Motors and electric pumps

Abstract

To reduce the number of components in a power line.SOLUTION: A motor includes: a rotor that is rotatable about a rotation shaft; a stator including a core disposed to face the rotor, and a coil having a conductive wire wound around a part of the core, an end of the conductive wire being drawn from the core to one side of an axis direction in which the rotation shaft extends; a housing including a housing bottom portion on the one side, housing the rotor and the stator, and having, in the housing bottom portion, a first through hole through which the end of the conductive wire passes; an insulating case that is disposed on the one side of the housing, has a case bottom portion on the housing side, and has, in the case bottom portion, a second through hole through which the end of the conductive wire passes after passing through the first through hole; and a connection terminal that includes a first connection portion connected to the conductive wire in the insulating case, and a second connection portion connected, in the insulating case, to a lead wire to be drawn to the outside of the motor, and is fixed to the insulating case.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a motor and an electric pump. [Background technology]

[0002] 2. Description of the Related Art Conventionally, in motors and electric pumps, a structure is known in which a rotor and a stator are housed within a motor housing, and ends of a coil wire of the stator are pulled out from within the motor housing to the outside of the motor housing.

[0003] For example, Patent Document 1 shows a structure in which a rotor and a stator are housed in a housing, lead wires of the stator coil are connected to conductive terminals at a cluster block inside the housing, the conductive terminals are pulled out from the housing and connected to cables inside the inverter cover, and the cables are connected to a motor drive circuit inside the inverter cover. A conductor that supplies driving power for the motor from an external source is further connected to the motor drive circuit. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2014-088871 A Summary of the Invention [Problem to be solved by the invention]

[0005] According to the structure of Patent Document 1, a large number of parts are required to form a power line for supplying driving power from the outside to the stator coil, and the assembly process is lengthy and the cost is high. Therefore, an object of the present invention is to reduce the number of parts in a power line. [Means for solving the problem]

[0006] One embodiment of a motor according to the present invention comprises a rotor rotatable on a rotating shaft, a core arranged to face the rotor, and a stator having a coil with a conductor wound around part of the core and an end of the conductor pulled out from the core to one side in the axial direction in which the rotating shaft extends, a housing having a housing bottom on the one side, housing the rotor and the stator inside and having a first through hole in the housing bottom through which the end of the conductor passes, an insulating case arranged on the one side of the housing, having a case bottom on the housing side and having a second through hole in the case bottom through which the end of the conductor that passed through the first through hole passes, and a connection terminal fixed to the insulating case, the connection terminal having a first connection part connected to the conductor within the insulating case and a second connection part connected within the insulating case to a lead wire pulled out to the outside of the motor. Moreover, one aspect of the electric pump according to the present invention includes the above-mentioned motor and a pump unit driven by the above-mentioned motor. Effect of the Invention

[0007] According to the present invention, the number of parts in the power line can be reduced. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram conceptually showing the structure of an oil pump. [Diagram 2] FIG. 2 is a diagram showing the structure of the stator. [Diagram 3] FIG. 3 is a diagram showing the inside of the sensor unit. [Figure 4] FIG. 4 is a diagram showing the overall structure of the metal terminals with the resin portion of the board case removed. [Diagram 5] FIG. 5 is a cross-sectional view showing the structure in the vicinity of the through hole. [Figure 6] FIG. 6 is a diagram showing a detailed structure of the first connection portion. [Figure 7] FIG. 7 is a view showing the first connection portion from a different direction than that of FIG. [Figure 8]FIG. 8 is a diagram showing a detailed structure of the second connection portion. [Figure 9] FIG. 9 is a diagram showing the positional relationship between the second connection portion and the lead wire. [Figure 10] FIG. 10 is a diagram showing a state in which the terminal portion of the lead wire is hooked onto the second connection portion. [Figure 11] FIG. 11 is a diagram showing a state in which the second portion of the second connection portion is bent. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, embodiments of the motor and electric pump of the present disclosure will be described in detail with reference to the accompanying drawings. However, in order to avoid the following description becoming unnecessarily redundant and to facilitate understanding by those skilled in the art, more detailed description than necessary may be omitted. For example, detailed description of already well-known matters and duplicated description of substantially the same configuration may be omitted. Furthermore, elements shown in the previously described figures may be appropriately referenced in the description of the later figures. FIG. 1 is a diagram conceptually showing the structure of an oil pump. The oil pump 100 corresponds to one embodiment of the electric pump of the present invention. The oil pump 100 includes a motor section 110, a sensor section 120, and a pump section 130. The motor unit 110 receives a supply of electric power and generates a rotational driving force. The sensor unit 120 detects the rotation of the motor unit 110 . The pump unit 130 is driven by the motor unit 110 and sucks and discharges oil. The combination of the motor section 110 and the sensor section 120 corresponds to one embodiment of the motor of the present invention, and the pump section 130 corresponds to one example of the pump section of the present invention. The motor section 110 includes a motor housing 111 , a rotating shaft 112 , a rotor 113 , a stator 114 , and a bearing 115 .

[0010] The rotating shaft 112 is a member that transmits the rotational driving force of the motor unit 110. In the following description, the rotating shaft 112 is used as a reference for direction, and the direction along the rotating shaft 112 may be referred to as the axial direction. In addition, in the following description, regardless of the direction shown in the figure, the upper side in FIG. 1 may be referred to as one axial side, and the lower side in FIG. 1 may be referred to as the other axial side. Furthermore, in the following description, the direction perpendicular to the rotation center line of the rotating shaft 112 that approaches and deviates from the rotation center line may be referred to as the radial direction, the side closer to the rotating shaft 112 may be referred to as the radial inner side, and the side farther from the rotating shaft 112 may be referred to as the radial outer side.

[0011] The motor housing 111 is a structure that supports the motor section 110 and the oil pump 100 as a whole, and is formed, for example, by pressing a metal plate. The motor housing 111 corresponds to an example of a housing according to the present invention, and accommodates a rotor 113 and a stator 114 inside. The motor housing 111 has a cylindrical section 111a extending in the axial direction and a bottom section 111b located on one axial side of the cylindrical section 111a. In other words, the motor housing 111 has the bottom section 111b on one axial side, and the bottom section 111b of the motor housing 111 corresponds to an example of a housing bottom according to the present invention. The cross-sectional shape of the cylindrical section 111a of the motor housing 111 is not particularly limited. The cross-sectional shape of the cylindrical section 111a may be, for example, a circular or elliptical round shape, a square or rectangular polygonal shape, or another polygonal shape such as a triangular or pentagonal shape.

[0012] The rotor 113 is fixed to the rotating shaft 112, has a permanent magnet built in, for example, and rotates together with the rotating shaft 112 by the action of a rotating magnetic field.

[0013] Stator 114 is accommodated in motor housing 111 facing rotor 113 and generates a rotating magnetic field. Note that, although this embodiment shows an inner rotor type structure in which stator 114 is disposed radially outside rotor 113, the motor of the present invention may have an outer rotor type structure in which stator 114 is disposed radially inside rotor 113.

[0014] The bearing 115 is, for example, a ball bearing, and holds the rotating shaft 112 rotatably. The bearing 115 may be a roller bearing, a sliding bearing, or the like. The bearings 115 are disposed on one axial side and the other axial side across the rotor 113, and the bearing 115 on the one axial side is fixed to, for example, the bottom part 111b of the housing 111. The bearing 115 on the other axial side is held by, for example, the pump part 130. The sensor unit 120 includes a board case 121 and a sensor board 122 .

[0015] The board case 121 corresponds to an example of an insulating case according to the present invention, and is disposed on one axial side of the motor housing 111. The board case 121 is made of, for example, resin, and has a bottom 121a on the motor housing 111 side.

[0016] Ends of conductors drawn from the coils of the stator 114 are guided to the board case 121, and in this embodiment, the board case 121 is used as a space for drawing out wiring to the motor unit 110. The board case 121 also houses and holds a sensor board 122 therein, for example.

[0017] The sensor board 122 has a magnetic sensor and detects, for example, the rotational position and rotational speed of the rotating shaft 112. The board case 121 may house a control board or an inverter board together with the sensor board 122 or instead of the sensor board 122.

[0018] The pump section 130 has a pump housing 131 and an actuating section 132. While the motor housing 111 has a bottom section 111b on one axial side, the pump section 130 is disposed on the other axial side of the motor housing 111. This makes it easy to join the pump section 130 to the rotating shaft 112, etc., and ultimately makes it easy to assemble the oil pump 100. The pump housing 131 accommodates an actuating portion 132 and is fixed to the motor housing 111 . The actuating portion 132 rotates within the pump housing 131 by the driving force of the rotating shaft 112 to suck in and discharge oil.

[0019] The pump section 130 corresponds to an example of the pump section according to the present invention. The pump section according to the present invention may have a structure different from that of the pump section 130 shown in FIG. 1, for example, a structure separated from the holding portion of the bearing 115. FIG. 2 is a diagram showing the structure of the stator.

[0020] The stator 114 has a core 141 arranged to face the rotor 113, and a coil 142 in which a conductor is wound around a part of the core 141 and an end 143 of the conductor is pulled out from the core 141 to one side in the axial direction. The end 143 of the coil 142 from which the conductor is pulled out is flexible, so that it is difficult for it to stand upright against gravity, or even if it does stand upright, it is unstable. As a three-phase motor is used as an example in this embodiment, the coil 142 has a total of three sets of conductor ends 143 corresponding to the UVW phases.

[0021] When assembling the motor unit 110, the stator 114 is inserted into the motor housing 111, for example, from the other axial side. When inserting the stator 114, the end 143 of the conductor is located at the front of the insertion, and as the stator 114 is inserted, the end 143 of the conductor moves toward the bottom 111b of the motor housing 111. Then, the end 143 of the conductor is guided from the motor unit 110 side to the sensor unit 120 side.

[0022] In order to ensure the strength of the structure, a metal material is usually used for the motor housing 111. For this reason, insulation between the end 143 of the conductor and the motor housing 111 is required. FIG. 3 is a diagram showing the inside of the sensor unit 120. As shown in FIG.

[0023] 3 shows a state in which one axial side of the board case 121 is open, and inside the sensor unit 120, a sensor board 122 housed in the board case 121 and metal terminals 123 embedded in a bottom 121a of the board case 121 are arranged. The board case 121 has a through hole 121b in the bottom 121a through which an end 143 of a conductor passes. Three sets of metal terminals 123 and through holes 121b are provided corresponding to the UVW phases of the motor.

[0024] The metal terminal 123 corresponds to an example of a connection terminal according to the present invention, and is connected to the end 143 of the conductor. In this embodiment, the metal terminal 123 is fixed to the board case 121 by being integrally molded with the board case 121 by insert molding. In other words, the metal terminal 123 is embedded in the bottom 121a of the board case 121 and is integrated with the board case 121.

[0025] The metal terminal 123 may be fixed to the board case 121 by a method such as a snap fit or by inserting a resin positioning protrusion into a positioning hole of the terminal and melting the positioning protrusion. However, by integrally molding the metal terminal 123 with the board case 121, the number of parts is further reduced and the task of fixing the metal terminal 123 to the board case 121 is also eliminated. FIG. 4 is a diagram showing the overall structure of metal terminal 123 with the resin portion of board case 121 removed.

[0026] 4, the resin portion of the board case 121 has been removed to show the bottom 111b of the motor housing 111. The motor housing 111 has a through hole 111c in the bottom 111b through which the end 143 of the conductor passes.

[0027] Metal terminal 123 has first connection portion 123a at one end and second connection portion 123b at the other end. Metal terminal 123 is embedded in bottom portion 121a of substrate case 121 except for first connection portion 123a and second connection portion 123b, and first connection portion 123a and second connection portion 123b of metal terminal 123 protrude from bottom portion 121a of substrate case 121 toward the inside of substrate case 121. The structures of first connection portion 123a and second connection portion 123b will be described in detail later.

[0028] End 143 of the conductor passes through through hole 111c provided in bottom 111b of motor housing 111 as shown in Fig. 3 and through hole 121b provided in bottom 121a of board case 121 as shown in Fig. 4 to reach inside board case 121. That is, end 143 of the conductor that passed through through hole 111c of motor housing 111 passes through through hole 121b of board case 121.

[0029] Because the opening of through hole 121b of board case 121 is smaller than that of through hole 111c of motor housing 111, end 143 of the conductor is insulated from motor housing 111 by board case 121. Here, the structure near through holes 111c and 121b will be described in detail. FIG. 5 is a cross-sectional view showing the structure in the vicinity of the through holes 111c and 121b.

[0030] The board case 121 has a cylindrical portion 121c that protrudes toward the motor housing 111 and extends into the through hole 111c of the motor housing 111, and the through hole 121b of the board case 121 passes through the cylindrical portion 121c. In other words, the board case 121 has a cylindrical portion 121c that protrudes to the other axial side and extends into the through hole 111c of the motor housing 111, and through which the through hole 121b of the board case 121 passes. By providing such a cylindrical portion 121c, the end 143 of the conductor is suitably insulated from the motor housing 111, and a separate member for insulation is not required, thereby further reducing the number of parts, labor, and costs.

[0031] Furthermore, the tip of the cylindrical portion 121c (i.e., the end portion on the other axial direction) protrudes further to the other axial direction side than the end face 115a on one axial direction side of the bearing 115 fixed to the motor housing 111. By having the cylindrical portion 121c protrude to such a position, the end portion 143 of the conductor is more suitably insulated from the motor housing 111 compared to a case in which the protrusion is shorter. The description will continue below with reference to FIGS.

[0032] An end 143 of the conductor is fixed to a first connection portion 123a of the metal terminal 123 inside the substrate case 121 and is electrically connected to the metal terminal 123. That is, the conductor of the stator 114 is connected to the first connection portion 123a inside the substrate case 121.

[0033] One end of a lead wire 124 is housed inside the board case 121 and is drawn out to the outside of the board case 121 (i.e., to the outside of the motor consisting of the motor section 110 and the sensor section 120). The lead wire 124 has a coated wire section 124a in which a metal wire is coated with a resin coating, and a terminal section 124b connected to the metal wire, and supplies power to the motor section 110. The terminal section 124b of the lead wire 124 is fixed to a second connection section 123b of the metal terminal 123 and is electrically connected to the metal terminal 123. That is, the lead wire 124 is connected to the second connection section 123b inside the board case 121.

[0034] Since the end 143 of the conductor and the lead wire 124 are electrically connected by the metal terminal 123, the number of parts forming the power line to the motor unit 110 is reduced, and thus the cost is reduced. FIG. 6 is a diagram showing a detailed structure of first connecting portion 123a, and FIG. 7 is a diagram showing first connecting portion 123a from a different direction from that of FIG. The first connection portion 123a has a structure that protrudes from the outside to the inside of the through hole 121b of the substrate case 121.

[0035] More specifically, the first connection portion 123a has a first portion 151 whose end protruding inside the through hole 121b rises up to one axial side, a second portion 152 extending along the bottom 121a of the substrate case 121 following the first portion 151, and a third portion 153 folding back following the second portion 152 in the opposite direction from the direction in which the second portion 152 extended.

[0036] The end 143 of the conductor is sandwiched and crimped between the second portion 152 and the third portion 153 of the first connection portion 123a inside the board case 121. As a result, the end 143 of the conductor is fixed to the first connection portion 123a and is electrically connected to the first connection portion 123a. Furthermore, the end 143 of the conductor is firmly fixed to the first connection portion 123a by soldering.

[0037] Since first connection portion 123a protrudes to the inside of through hole 121b, end portion 143 of the conductor is connected to first connection portion 123a on an extension of through hole 121b, which makes it easy to route end portion 143. Also, second portion 152 and third portion 153 are held on one axial side with respect to through hole 121b by first portion 151 rising on one axial side, which makes it easy to perform crimping or soldering operations for connecting end portion 143 of the conductor to first connection portion 123a. FIG. 8 is a diagram showing a detailed structure of second connection portion 123b, and FIG. 9 is a diagram showing the positional relationship between second connection portion 123b and lead wire 124. As shown in FIG.

[0038] The second connection portion 123b protrudes in a plate shape from the bottom portion 121a of the substrate case 121 toward one side in the axial direction, and the substrate case 121 has a pedestal portion 121d that protrudes from the bottom portion 121a around the second connection portion 123b and surrounds the second connection portion 123b. In other words, the pedestal portion 121d surrounds the second connection portion 123b that protrudes toward one side in the axial direction from the bottom portion 121a of the substrate case 121 and protrudes toward one side in the axial direction to a position halfway up the second connection portion 123b. The pedestal portion 121d reinforces the second connection portion 123b.

[0039] The plate-shaped second connection portion 123b extends in a protruding direction H protruding from the bottom portion 121a of the substrate case 121, and also extends in an extending direction W along the bottom portion 121a of the substrate case 121.

[0040] The second connection portion 123b has a first portion 161 protruding from one side in the extension direction and extending toward one side in the axial direction, and a third portion 163 protruding from the other side in the extension direction away from the first portion 161. The second connection portion 123b also has a second portion 162 that protrudes toward the other side in the extension direction along the bottom portion 121a of the board case 121 at an end of the first portion 161 protruding toward one side in the axial direction. A V-shaped groove 164 is provided at the boundary between the first portion 161 and the second portion 162.

[0041] Terminal portion 124b of lead wire 124 connected to second connection portion 123b has a rectangular long hole 124c, and terminal portion 124b is hung on second connection portion 123b such that long hole 124c straddles first portion 161 and third portion 163 of second connection portion 123b. This determines the orientation and position of lead wire 124 relative to second connection portion 123b. By hanging terminal portion 124b of lead wire 124 on second connection portion 123b and temporarily holding it there, subsequent soldering work and the like becomes easier.

[0042] A guide protrusion 121e protruding from the bottom 121a to one side in the axial direction is provided on the substrate case 121. The guide protrusion 121e guides the lead wire 124 inside the substrate case 121, thereby stabilizing the routing route of the lead wire 124 inside the substrate case 121 and suppressing contact of other lead wires 124 with the second connection portion 123b and the terminal portion 124b. 10 and 11 are diagrams showing a procedure for connecting the terminal portion 124b of the lead wire 124 to the second connection portion 123b. FIG. 10 shows a state in which terminal portion 124b of lead wire 124 is hung on second connection portion 123b.

[0043] As described above, terminal portion 124b of lead wire 124 is adapted to straddle first portion 161 and third portion 163 of second connection portion 123b, and as a result, second portion 162 of second connection portion 123b penetrates terminal portion 124b of lead wire 124 to one axial side and protrudes from terminal portion 124b of lead wire 124.

[0044] The above-mentioned base portion 121d prevents terminal portion 124b of lead wire 124 from dropping toward bottom portion 121a of board case 121 when terminal portion 124b is hung on second connection portion 123b, facilitating the work of hanging terminal portion 124b on second connection portion 123b. Terminal portion 124b hung on second connection portion 123b is supported at a position away from bottom portion 121a, facilitating subsequent soldering work and the like. As shown in FIG. 10, after the terminal portion 124b of the lead wire 124 is hung on the second connection portion 123b, the second portion 162 of the second connection portion 123b is bent. FIG. 11 shows a state in which the second portion 162 of the second connection portion 123b is bent.

[0045] The second portion 162 protruding from the terminal portion 124b of the lead wire 124 is folded at the V-groove 164. By a subsequent soldering operation, the terminal portion 124b is fixed to the second connection portion 123b and the lead wire 124 is electrically connected to the second connection portion 123b. The bending of the second portion 162 prevents the terminal portion 124b from coming loose, facilitating the soldering operation.

[0046] Note that, although an oil pump is given as an example of a method of using the motor and electric pump of the present invention, the method of using the motor and electric pump of the present invention is not limited to the above. The electric pump of the present invention can be used as a pump that sucks in and discharges water, air, etc., and the motor of the present invention can be used in a wide range of applications such as power steering devices and compressors.

[0047] The above-described embodiment should be considered as illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims, not by the above-described embodiment, and is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0048] 100: Oil pump 110: Motor section 111: Motor housing 111a: Cylinder part 111b: Bottom 111c: Through hole 112: Rotation axis 113: Rotor 114: Stator 115: Bearings 120: Sensor section 121: Circuit board case 121a: Bottom 121b: Through hole 121c:Cylinder part 121d: Base 121e: Guide protrusion 122: Sensor board 123: Metal terminal 123a: First connection part 123b: Second connection part 124: Lead wire 151: First portion of first connection part 152: Second part of first connection part 153: Third part of first connection part 161: First part of second connection part 162: Second part of second connection part 163: Third part of second connection part 130: Pump section 131: Pump housing 132: Operating unit 141: Core 142: Coil 143: End of conductor

Claims

1. A rotor rotatable on a rotating shaft; a stator including a core disposed to face the rotor, and a coil having a conductor wound around a portion of the core, the end of the conductor being drawn out from the core to one side in the axial direction in which the rotating shaft extends; a housing having a housing bottom on the one side, accommodating the rotor and the stator therein, and having a first through hole in the housing bottom through which an end of the conductor passes; an insulating case disposed on the one side of the housing, having a case bottom on the housing side, and having a second through hole in the case bottom through which an end of the conductor that has passed through the first through hole passes; a connection terminal fixed to the insulating case, the connection terminal having a first connection portion connected to the conductor within the insulating case and a second connection portion connected to a lead wire drawn out to the outside of the motor within the insulating case; A motor in which the insulating case has a cylindrical portion that protrudes toward the other side relative to the one side and extends into the first through hole, and through which the second through hole passes.

2. 2. The motor according to claim 1, wherein the insulating case is made of resin, and the connection terminals are integrally formed with the insulating case.

3. a bearing that rotatably holds a rotation shaft of the rotor and is fixed to the bottom of the housing; The motor according to claim 1 , wherein the cylindrical portion protrudes beyond the end face on the one side of the bearing to the other side.

4. The motor according to claim 1 , wherein the second connection portion protrudes from the bottom of the case toward the one side.

5. The motor according to claim 4 , wherein the second connection portion has an overhanging portion at the end protruding to the one side, the overhanging portion overhanging along the bottom of the case.

6. 6. The motor according to claim 4, wherein the insulating case has a base portion surrounding the second connection portion protruding to the one side and protruding from the bottom of the case to the one side halfway up the second connection portion.

7. The motor according to claim 1 , wherein the first connection portion protrudes from an outer side to an inner side of the second through hole.

8. The motor described in claim 7, wherein the first connection portion has an end portion protruding into the inside of the second through hole, the end portion having a first portion rising toward the one side, a second portion extending along the bottom of the case following the first portion, and a third portion folding back following the second portion in the opposite direction to the direction in which the second portion extended.

9. 9. The motor according to claim 1, wherein the insulating case has a guide protrusion protruding from a bottom of the case to the one side for guiding the lead wires within the insulating case.

10. A motor according to any one of claims 1 to 9; and a pump section driven by the motor.

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