Motor device

Abstract

To provide a motor device capable of improving wiring workability to a coil holder of a coil lead-out part.SOLUTION: A oil holder 80 is provided with first, second, and third eaves parts 83a, 84a, 85a which partially cover a plurality of circumferential direction extension parts Cu, Cv, Cw from an axial direction one side of a stator, and when the coil holder 80 is viewed from the axial direction one side of the stator, the plurality of bent parts Pu, Pv, Pw are partially and visually recognizable. Then, the plurality of bent parts Pu, Pv, Pw can partially and easily be formed, accordingly, wiring workability to the coil holder 80 of U phase, V phase, W phase leading-out parts 70u1 to 70u8, 70v1 to 70v8, 70w1 to 70w8 can be improved more than conventional one, and accordingly, assembly workability of a brushless motor can be improved.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a motor device having a stator around which a plurality of coils are wound, and a rotor that rotates relative to the stator. [Background technology]

[0002] A motor device having a stator around which multiple coils are wound and a rotor that rotates relative to the stator is described in, for example, Patent Document 1. The electric motor (motor device) described in Patent Document 1 includes a stator and a rotor, and multiple teeth are provided on the radially inner side of the stator. In addition, coils are wound around each of the multiple teeth in a concentrated winding manner via insulators.

[0003] The ends of the coils wound around each tooth are pulled out to one axial side of the stator by a certain length, and these coil pull-out portions are arranged along multiple stepped portions provided in the holder portion. Furthermore, each coil pull-out portion arranged in the holder portion is connected to a terminal holder provided near the holder portion. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2014-187797 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the motor device described in the above-mentioned Patent Document 1, a holder part (coil holder) is provided with multiple flange parts, and these flange parts cover all the bent parts of the coil lead-out parts drawn out from the stator from the axial direction of the stator. Therefore, when the coil lead-out parts drawn out from the stator are bent and arranged along the stepped parts of the holder part, the flange parts of the holder part get in the way, which may reduce the workability of assembling the motor device.

[0006] An object of the present invention is to provide a motor device capable of improving the ease of wiring a coil lead-out portion to a coil holder. [Means for solving the problem]

[0007] In one aspect of the present invention, a motor device includes a stator around which a plurality of coils are wound, and a rotor that rotates relative to the stator, wherein each of the coils is provided with a coil lead-out portion that is led out to one axial side of the stator, and the coil lead-out portion includes an axial extending portion that extends in the axial direction of the stator, a circumferential extending portion that extends in the circumferential direction of the stator, and a bent portion that is provided between the axial extending portion and the circumferential extending portion, and the plurality of coil lead-out portions are each held on one axial side of the stator. a coil holder is provided, the coil holder has a plurality of first support portions arranged in a circumferential direction of the coil holder and supporting the plurality of axially extending portions, a plurality of second support portions arranged in a circumferential direction of the coil holder and supporting the plurality of circumferentially extending portions, and a covering wall arranged to extend in the circumferential direction of the coil holder and partially covering the plurality of circumferentially extending portions from one axial side of the stator, and when the coil holder is viewed from the one axial side of the stator, some of the plurality of bent portions are visible. a terminal connection portion that protrudes radially outward from the stator and is electrically connected to a power supply terminal is provided on the opposite side of the circumferential extending portion in the longitudinal direction from the bent portion, and the covering wall covers a part of the terminal connection portion from one axial side of the stator. It is characterized by the above. Effect of the Invention

[0008] According to the present invention, the coil holder is provided with a covering wall that partially covers the multiple circumferential extending portions from one axial side of the stator, and some of the multiple bent portions are visible when the coil holder is viewed from one axial side of the stator. This makes it possible to easily form some of the multiple bent portions, thereby improving the ease of arranging the coil pull-out portions in the coil holder compared to the conventional art. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a perspective view of the brushless motor as viewed from the cover member side. [Diagram 2] FIG. 11 is a diagram in which the cover member is omitted. [Diagram 3] FIG. 3 is a cross-sectional view taken along line AA in FIG. 2. [Figure 4] FIG. 2 is an exploded perspective view showing a stator and a coil holder. [Diagram 5] 13(a) and 13(b) are perspective views showing U-phase, V-phase, and W-phase lead-out portions and a coil holder. [Figure 6] 5(a) and 5(b) are perspective views of the U-phase, V-phase, and W-phase lead-out portions from which the coil holders are omitted from FIGS. [Figure 7] 13(a), (b), and (c) are views of the U-phase, V-phase, and W-phase lead-out portions as viewed from one axial side of the stator. [Figure 8] 4A and 4B are perspective views showing the coil holder alone. [Figure 9] 13(a) and 13(b) are diagrams illustrating a procedure for installing a U-phase lead-out portion (a part on one radial side) in a coil holder. FIG. [Figure 10] 13(a) and 13(b) are diagrams illustrating a procedure for installing a U-phase lead-out portion (a part on the other radial side) in a coil holder. [Figure 11] 13(a) and 13(b) are diagrams illustrating a procedure for installing a V-phase lead-out portion (a part on one radial side) in a coil holder. [Figure 12]13(a) and 13(b) are diagrams illustrating a procedure for installing a W-phase lead-out portion (a part on one radial side) in a coil holder. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

[0011] Figure 1 is an oblique view of the brushless motor seen from the cover member side, Figure 2 is a view without the cover member shown, Figure 3 is a cross-sectional view along line AA in Figure 2, Figure 4 is an exploded oblique view showing the stator and coil holder, Figures 5(a) and (b) are oblique views showing the U-phase, V-phase, and W-phase lead-out portions and the coil holder, Figures 6(a) and (b) are oblique views of the U-phase, V-phase, and W-phase lead-out portions from Figures 5(a) and (b) with the coil holder omitted, Figures 7(a), (b), and (c) are views of the U-phase, V-phase, and W-phase lead-out portions seen from one axial side of the stator, and Figures 8(a) and (b) are oblique views showing the coil holder alone.

[0012] The brushless motor (motor device) 10 shown in Figures 1 to 3 is a motor device used as a drive source for an electric motorcycle or the like. Specifically, the brushless motor 10 is attached to a vehicle frame and drives the axle of a drive wheel via a chain or belt. Note that the brushless motor 10 can also be attached directly to the axle of the drive wheel.

[0013] The brushless motor 10 includes a housing 20 that forms the outer shell of the brushless motor 10. The housing 20 includes an aluminum housing main body 21 that is formed into a substantially cylindrical shape with a bottom, and an aluminum cover member 22 that is formed into a substantially circular plate shape.

[0014] 3, a motor unit 30 is accommodated inside the housing 20. The motor unit 30 includes a stator 40 fixed to the inside of the housing body 21, and a rotor 50 that rotates radially inside the stator 40 via a minute gap (air gap).

[0015] As shown in Fig. 4, stator 40 is formed into a generally cylindrical shape by connecting a plurality of split cores 60 in an annular shape. Here, stator 40 in the present embodiment is formed into a generally cylindrical shape by connecting a total of 12 split cores 60. Coils 70 corresponding to U-phase, V-phase, and W-phase are wound by concentrated winding around teeth 61 (see Fig. 3) forming split core 60, with insulators 62 interposed therebetween.

[0016] The multiple split cores 60 are arranged alternately in the circumferential direction of the stator 40 as U-phase, V-phase, W-phase, U-phase, V-phase, W-phase, etc., and further, the U-phase, V-phase and W-phase coils 70 wound by concentrated winding around the multiple split cores 60 are each "delta connected." This eliminates the need for a coil or conductive member that forms a neutral point, which is necessary for "star connection," and allows for a simplification of the structure of the brushless motor 10. However, depending on the specifications required for the brushless motor 10, it is also possible to "star connect" each of the U-phase, V-phase and W-phase coils 70 by providing an additional coil or conductive member that forms a neutral point.

[0017] The coil 70 is made of aluminum, for example, and is formed of a so-called "rectangular wire" having a rectangular (approximately rectangular) cross section in a direction intersecting the longitudinal direction. This allows the coil 70 to be wound around the stator 40 in an orderly manner without gaps, thereby improving the space factor. The surface of the coil 70 is coated with enamel paint (not shown) for insulation.

[0018] Then, U-phase led-out portions 70u1-70u8 forming the U-phase coil 70, V-phase led-out portions 70v1-70v8 forming the V-phase coil 70, and W-phase led-out portions 70w1-70w8 forming the W-phase coil 70 are led out to one axial side of the stator 40. Specifically, the led-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 (a total of 24) are extended to one axial side of the stator 40 as shown in Fig. 4. Here, the U-phase, V-phase, and W-phase led-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 correspond to the coil led-out portions in the present invention.

[0019] Furthermore, an annular coil holder 80 is provided on one axial side of the stator 40 (upper side in Figs. 3 and 4). As shown in Figs. 5(a) and 5(b), the coil holder 80 has the lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 arranged therein. That is, the coil holder 80 holds the U-phase, V-phase, and W-phase lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8, respectively. The U-phase power terminal Tu, the V-phase power terminal Tv, and the W-phase power terminal Tw (see Fig. 2) are electrically connected to these lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8, respectively. Here, the U-phase, V-phase, and W-phase power terminals Tu, Tv, and Tw correspond to the power terminals in the present invention.

[0020] The detailed structures of U-phase, V-phase, and W-phase extended portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 and coil holder 80 will be described later. In addition, in Figures 5 to 7 and 9, U-phase, V-phase, and W-phase extended portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 are shaded in different intensities to make them easier to see.

[0021] 3, the rotor 50 includes a rotor body 51 formed into a generally cylindrical shape by laminating a plurality of steel plates (magnetic bodies). A rotating shaft 52 is fixed to the center of rotation of the rotor body 51, and the rotating shaft 52 rotates together with the rotor body 51. A plurality of magnets 53 formed into a generally plate shape are embedded inside the rotor body 51. The magnets 53 are arranged such that N poles and S poles alternate in the circumferential direction of the rotor body 51.

[0022] However, this is not limited to the so-called "IPM (Interior Permanent Magnet) structure" in which multiple magnets 53 are embedded inside the rotor body 51 as described above, but it is also possible to adopt a so-called "SPM (Surface Permanent Magnet) structure" in which a magnet (not shown) is attached to the surface of the rotor body 51.

[0023] A sensor magnet 54 formed in a substantially disk shape is fixed to one axial side of the rotating shaft 52. The sensor magnet 54 is used to detect the rotation state of the rotor 50 (rotating shaft 52). The sensor magnet 54 faces a rotation sensor 56 provided on a sensor board 55 in the axial direction of the rotor 50.

[0024] One axial side of the rotating shaft 52 is rotatably supported by a first ball bearing BB1 mounted in a bearing holder 57. On the other hand, the other axial side (the lower side in FIG. 3) of the rotating shaft 52 is rotatably supported by a second ball bearing BB2 mounted in the housing body 21.

[0025] The housing body 21 has a bottom wall portion 21a formed in a substantially circular plate shape. A bearing mounting portion 21b and a seal mounting portion 21c formed in a substantially cylindrical shape are integrally provided at the center portion of the bottom wall portion 21a. An outer ring of a second ball bearing BB2 is mounted on the radial inside of the bearing mounting portion 21b, and a rubber lip seal LS is mounted on the radial inside of the seal mounting portion 21c. The inner ring of the second ball bearing BB2 is mounted on the other axial side of the rotating shaft 52, and the lip seal LS is in contact with the outer periphery of the rotating shaft 52. This prevents rainwater, dust, and the like from entering the inside of the housing 20.

[0026] The housing body 21 includes a cylindrical wall portion 21d formed in a substantially cylindrical shape. The other axial side of the cylindrical wall portion 21d is integrally provided on the radially outer side of the bottom wall portion 21a. A stator 40 is press-fitted into the radially inner side of the cylindrical wall portion 21d and firmly fixed thereto by adhesive or the like. A plurality of cooling fins 21e that dissipate heat generated by driving the brushless motor 10 to the outside of the housing body 21 are integrally provided on the radially outer side of the cylindrical wall portion 21d.

[0027] Furthermore, the housing body 21 includes a polygonal wall portion 23. The polygonal wall portion 23 is integrally provided on one axial side (upper side in FIG. 3) of the cylindrical wall portion 21d so as to be coaxial with the cylindrical wall portion 21d. As shown in FIG. 2, the polygonal wall portion 23 is a substantially regular hexagon when the housing body 21 is viewed from one axial side. The polygonal wall portion 23 includes a first side portion 23a, a second side portion 23b, a third side portion 23c, a fourth side portion 23d, a fifth side portion 23e, and a sixth side portion 23f. The stator 40 and the rotor 50 are assembled into the housing body 21 through the opening of the polygonal wall portion 23.

[0028] A driving connector 24 is attached to the first side portion 23a, and the driving connector 24 is provided on one axial side of the housing 20. The driving connector 24 has a connector block 24a made of a resin material such as plastic, and the connector block 24a is fixed to the first side portion 23a by a fixing screw or the like (not shown).

[0029] The connector block 24a is disposed outside the housing 20, and specifically, protrudes radially outward from the polygonal wall portion 23. A U-phase power supply terminal Tu, a V-phase power supply terminal Tv, and a W-phase power supply terminal Tw are provided and exposed inside the connector block 24a.

[0030] The U-phase power supply terminal Tu is electrically connected to one end of a U-phase electric wire Eu, the other end of which is electrically connected to the controller CU. The V-phase power supply terminal Tv is electrically connected to the other end of a V-phase electric wire Ev, the other end of which is electrically connected to the controller CU. The W-phase power supply terminal Tw is electrically connected to the other end of a W-phase electric wire Ew, the other end of which is electrically connected to the controller CU. This allows drive current to be supplied to the coils 70 wound around the stator 40 and corresponding to the U-phase, V-phase, and W-phase.

[0031] As shown in FIG. 2, the polygonal wall portion 23 is integrally provided with a protrusion 25 that protrudes radially outward from the housing 20. Specifically, the protrusion 25 protrudes radially outward from the second side portion 23b provided next to the first side portion 23a. The protrusion 25 has a substantially triangular bottom wall 25a. The protrusion 25 also has a first side wall 25b and a second side wall 25c. In this way, the protrusion 25 is formed by being surrounded by the bottom wall 25a, the first side wall 25b, the second side wall 25c, and the second side portion 23b, and a connection space SP is formed inside the protrusion 25. The opening of the protrusion 25 is also closed by the cover member 22.

[0032] The connection space SP is a portion into which the controller side connector portion 43 of the board wire harness 42 fits. The connection space SP has a function of guiding the controller side connector portion 43 to the board connector 26 when connecting the controller side connector portion 43 to the board connector 26. Therefore, when assembling the brushless motor 10, the controller side connector portion 43 can be easily connected to the board connector 26.

[0033] 1 and 3, the cover member 22 includes a main cover portion 22a that closes the opening of the polygonal wall portion 23, and a sub-cover portion 22b that closes the opening of the protrusion 25. The main cover portion 22a and the sub-cover portion 22b are integral with each other, and the main cover portion 22a is formed in a substantially circular plate shape, while the sub-cover portion 22b is formed in a substantially triangular plate shape. The cover member 22 is firmly fixed to the housing main body 21 by a total of seven fixing bolts BT that are distributed around the periphery of the cover member 22.

[0034] A connector fixing portion 25d is integrally provided on a first side wall 25b of the protrusion 25 so as to protrude radially outward from the housing 20. A board connector 26 is attached to the connector fixing portion 25d. The board connector 26 is made of a resin material such as plastic and includes a fixing plate portion 26a formed in a substantially flat plate shape. The fixing plate portion 26a is fixed to the connector fixing portion 25d by a pair of first screws S1.

[0035] The board connector 26 also includes an inner connection portion (not shown) formed in a substantially box shape and an outer connection portion 26b. The inner connection portion is disposed inside the housing 20, and the outer connection portion 26b is disposed outside the housing 20.

[0036] A controller-side connector portion 43 of a board wire harness 42 is connected to the inner connection portion of the board connector 26 in the connection space SP on the inner side of the protrusion 25. One end of a board electric wire SE (see FIG. 2) is electrically connected to the controller CU at the other end thereof to the outer connection portion 26b of the board connector 26.

[0037] 1 and 2, the connector block 24a and the outer connection portion 26b arranged outside the housing 20 face the same direction (upward in FIG. 2). The drive connector 24 and the board connector 26 are arranged adjacent to each other in a horizontal row. This allows the U-phase, V-phase, and W-phase electric wires Eu, Ev, and Ew and the board electric wire SE to be easily connected to the drive connector 24 and the board connector 26, respectively.

[0038] 2 and 3, an aluminum bearing holder 57 formed in a substantially regular hexagonal plate shape is provided on one axial side of the housing body 21 (the upper side in FIG. 3). The bearing holder 57 is disposed radially inside the polygonal wall portion 23 and holds a first ball bearing BB1. Specifically, the first ball bearing BB1 is mounted on a retaining cylinder 57a formed in the center of the bearing holder 57. The bearing holder 57 is firmly fixed to one axial side of the housing body 21 by a total of six first fixing bolts B1.

[0039] Further, an annular support plate 57b is provided in the center of the bearing holder 57 on the opposite side to the rotor 50 side to prevent the first ball bearing BB1 from falling off the retaining cylinder 57a. The support plate 57b holds down the outer ring of the first ball bearing BB1. This ensures smooth operation of the first ball bearing BB1. The support plate 57b is fixed to the bearing holder 57 by a total of four second fixing bolts B2 (only three are shown in FIG. 2).

[0040] Furthermore, a total of four support columns 57c are provided around the first ball bearing BB1 on the side of the bearing holder 57 opposite the rotor 50. The sensor board 55 is fixed to the tips of these support columns 57c. Specifically, the sensor board 55 is fixed to a pair of support columns 57c arranged diagonally by a pair of second screws S2.

[0041] Here, the sensor board 55 is a printed circuit board (PCB) formed in a substantially square shape. A rotation sensor 56 made of a magnetic resistance element is provided in the center of the sensor board 55. The rotation sensor 56 faces a sensor magnet 54 fixed to one axial side of the rotating shaft 52 across a small gap (see FIG. 3). In this way, the rotation sensor 56 detects the rotation state (rotation direction, rotation speed, etc.) of the rotating shaft 52.

[0042] The sensor board 55 is also provided with a board-side connection portion 58 to which the board-side connector portion 44 of the board wire harness 42 is connected. The board-side connection portion 58 faces the connection space SP of the protrusion 25, as shown in Fig. 2. This makes it possible to easily connect the board-side connector portion 44 to the board-side connection portion 58.

[0043] Here, the board wire harness 42 is provided between the sensor board 55 and the board connector 26, and has a function of electrically connecting the controller CU (see FIG. 2) and the sensor board 55 inside the housing 20. Therefore, a detection signal of the rotation sensor 56 is sent to the controller CU via the board wire harness 42 and the board electric wire SE.

[0044] As shown in Figures 5(a) and 5(b), U-phase, V-phase, and W-phase lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 that respectively form coils 70 corresponding to the U-phase, V-phase, and W-phase are each arranged in a coil holder 80. Note that each of the lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 (a total of 24) is arranged in the coil holder 80 so that different phases are not short-circuited with each other.

[0045] The structures of the U-phase, V-phase, and W-phase lead-out portions 70u1 to 70u8, 70v1 to 70v8, and 70w1 to 70w8 and the coil holder 80 will be described in detail below with reference to the drawings.

[0046] As shown in Figs. 6(a), (b) and 7(a), the U-phase lead portions 70u1 to 70u8 (total of eight) each include an axial extension portion Au extending in the axial direction of the stator 40 (see Fig. 4), a circumferential extension portion Cu extending in the circumferential direction of the stator 40, and a bent portion Pu provided between the axial extension portion Au and the circumferential extension portion Cu. A terminal connection portion Nu protruding in the radial direction of the stator 40 and electrically connected to a U-phase power supply terminal Tu (see Fig. 2) is provided on the opposite side of the circumferential extension portion Cu from the bent portion Pu in the longitudinal direction. The terminal connection portion Nu is formed into a substantially rectangular shape as viewed in the axial direction of the stator 40, as shown in Fig. 7(a), by binding the total of eight U-phase lead portions 70u1 to 70u8 together with an adhesive or the like. However, the method of fastening the terminal connection portions Nu is not limited to adhesives, and may be thermal caulking (welding) or the like.

[0047] As shown in Figure 7(a), when the U-phase lead-out portions 70u1-70u8 are viewed from one axial side of the stator 40, these U-phase lead-out portions 70u1-70u8 have a mirror-symmetric shape on one radial side (left side in the figure) and the other radial side (right side in the figure) of the stator 40, centered on a first reference line (reference line) BP1 that passes through the axis Cn of the stator 40 and the center of the terminal connection portion Nu in the circumferential direction of the stator 40.

[0048] Specifically, U-phase lead-out portions 70u1 and 70u7 are formed in the same shape around the first reference line BP1, U-phase lead-out portions 70u2 and 70u8 are formed in the same shape around the first reference line BP1, U-phase lead-out portions 70u3 and 70u5 are formed in the same shape around the first reference line BP1, and U-phase lead-out portions 70u4 and 70u6 are formed in the same shape around the first reference line BP1.

[0049] This allows the length dimensions of each pair of U-phase extended portions 70u1-70u8 to be as uniform as possible, thereby enabling the magnitude of current flowing through each U-phase coil 70 to be well balanced, resulting in a brushless motor 10 with little rotational wobble. Note that the inner diameter d1 of U-phase extended portions 70u1-70u8 is approximately the same as the outer diameter of U-phase circumferential groove 83 (see FIGS. 5(a) and 8(a)) provided in coil holder 80.

[0050] As shown in Fig. 6(a), (b) and Fig. 7(b), V-phase lead-out portions 70v1 to 70v8 (total of eight) also include, like U-phase lead-out portions 70u1 to 70u8, an axially extending portion Av extending in the axial direction of stator 40, a circumferentially extending portion Cv extending in the circumferential direction of stator 40, and a bent portion Pv provided between axially extending portion Av and circumferentially extending portion Cv. Furthermore, a terminal connection portion Nv protruding in the radial direction of stator 40 is provided on the opposite side of the bent portion Pv in the longitudinal direction of circumferential extending portion Cv. A V-phase power supply terminal Tv (see Fig. 2) is electrically connected to the terminal connection portion Nv of V-phase lead-out portions 70v1 to 70v8.

[0051] 7(b), when V-phase lead-out portions 70v1-70v8 are viewed from one axial side of stator 40, these V-phase lead-out portions 70v1-70v8 have a mirror-image shape on one radial side and the other radial side of stator 40 about a second reference line (reference line) BP2 that passes through the axis Cn of stator 40 and through the center of the terminal connection portion Nv in the circumferential direction of stator 40. The second reference line BP2 is shifted by 30 degrees from the first reference line BP1.

[0052] V-phase lead-out portions 70v1 and 70v7 are formed in the same shape around the second reference line BP2, V-phase lead-out portions 70v2 and 70v8 are formed in the same shape around the second reference line BP2, V-phase lead-out portions 70v3 and 70v5 are formed in the same shape around the second reference line BP2, and V-phase lead-out portions 70v4 and 70v6 are formed in the same shape around the second reference line BP2.

[0053] This allows the length dimensions of each pair of V-phase lead-out portions 70v1-70v8 to be as uniform as possible, thereby enabling the magnitude of current flowing through each V-phase coil 70 to be well balanced, resulting in a brushless motor 10 with little rotational wobble. Note that the inner diameter d2 of V-phase lead-out portions 70v1-70v8 is approximately the same as the outer diameter of V-phase circumferential groove 84 (see Figs. 5(a) and 8(a)) provided in coil holder 80. Also, inner diameter d2 is larger than inner diameter d1 (see Fig. 7(a)) (d2>d1).

[0054] As shown in Figs. 6(a), 6(b) and 7(c), the W-phase lead-out portions 70w1 to 70w8 (total of eight) also include, like the U-phase lead-out portions 70u1 to 70u8, an axially extending portion Aw extending in the axial direction of the stator 40, a circumferentially extending portion Cw extending in the circumferential direction of the stator 40, and a bent portion Pw provided between the axially extending portion Aw and the circumferentially extending portion Cw. Furthermore, a terminal connection portion Nw protruding in the radial direction of the stator 40 is provided on the opposite side of the circumferentially extending portion Cw from the bent portion Pw in the longitudinal direction. A W-phase power supply terminal Tw (see Fig. 2) is electrically connected to the terminal connection portion Nw of the W-phase lead-out portions 70w1 to 70w8.

[0055] 7(c), when W-phase extended portions 70w1-70w8 are viewed from one axial side of stator 40, these W-phase extended portions 70w1-70w8 have mirror-image shapes on one radial side and the other radial side of stator 40 about a third reference line (reference line) BP3 that passes through the axis Cn of stator 40 and through the center of the terminal connection portion Nw in the circumferential direction of stator 40. The third reference line BP3 is offset by 60 degrees from the first reference line BP1.

[0056] W-phase lead-out portions 70w1 and 70w7 are formed in the same shape around the third reference line BP3, W-phase lead-out portions 70w2 and 70w8 are formed in the same shape around the third reference line BP3, W-phase lead-out portions 70w3 and 70w5 are formed in the same shape around the third reference line BP3, and W-phase lead-out portions 70w4 and 70w6 are formed in the same shape around the third reference line BP3.

[0057] This allows the length dimensions of each pair of W-phase extended portions 70w1-70w8 to be as uniform as possible, thereby enabling the magnitude of current flowing through each W-phase coil 70 to be well balanced, resulting in a brushless motor 10 with little rotational wobble. Note that the inner diameter d3 of W-phase extended portions 70w1-70w8 is approximately the same as the outer diameter of W-phase circumferential groove 85 (see Figs. 5(a) and 8(a)) provided in coil holder 80. Also, inner diameter d3 is larger than inner diameters d1 and d2 (see Figs. 7(a) and 7(b)) (d3>d2>d1).

[0058] As shown in Fig. 4, Fig. 5 and Fig. 8, the coil holder 80 is formed in a substantially annular shape from a resin material (insulating material) such as plastic. The coil holder 80 includes a cylindrical main body 81 formed in a substantially cylindrical shape, and a plurality of engaging protrusions 81a are integrally provided on the other axial side (lower side in the figures) of the cylindrical main body 81. These engaging protrusions 81a are disposed at equal intervals in the circumferential direction of the cylindrical main body 81, and are adapted to engage with a plurality of engaging recesses 45 (see Fig. 4) provided in the stator 40, respectively. As a result, the coil holder 80 is positioned in the axial direction of the stator 40, and is fixed in the circumferential direction of the stator 40 so as not to rotate relative to the stator 40.

[0059] Further, a plurality of first recesses 82 are provided on the radially outer side of the cylindrical main body 81. These first recesses 82 are provided so as to be recessed radially inward of the coil holder 80, and are arranged side by side in the circumferential direction of the coil holder 80. The first recesses 82 correspond to the first support portions in the present invention, and each of the first recesses 82 supports the axially extending portions Au, Av, and Aw (see FIG. 6(a)) in the lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 (see FIG. 5(a)). In this way, by having each of the axially extending portions Au, Av, and Aw supported individually by the first recesses 82, the axially extending portions Au, Av, and Aw can be arranged orderly so as to be arranged side by side in the circumferential direction of the coil holder 80.

[0060] Furthermore, each of the first recesses 82 is provided with an arc-shaped corner 82a that forms bent portions Pu, Pv, and Pw (see FIGS. 6(a) and 6(b)) when the lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 are arranged in the coil holder 80. Then, each of the bent portions Pu, Pv, and Pw is formed by bending the lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 along the corresponding arc-shaped corner 82a.

[0061] In this way, bending the bent portions Pu, Pv, Pw into an arc shape suppresses excessive force from being applied to the drawn-out portions 70u1-70u8, 70v1-70v8, 70w1-70w8. This prevents the enamel paint applied to the surfaces of the drawn-out portions 70u1-70u8, 70v1-70v8, 70w1-70w8 from peeling off. The procedure for arranging the drawn-out portions 70u1-70u8, 70v1-70v8, 70w1-70w8 in the coil holder 80 will be described in detail later.

[0062] Further, a U-phase circumferential groove 83, a V-phase circumferential groove 84, and a W-phase circumferential groove 85 are provided on the radial outside of the cylindrical main body portion 81. The U-phase circumferential groove 83, the V-phase circumferential groove 84, and the W-phase circumferential groove 85 correspond to second support portions in the present invention, and are provided side by side in the axial direction of the coil holder 80. The U-phase circumferential groove 83, the V-phase circumferential groove 84, and the W-phase circumferential groove 85 support the circumferential extending portions Cu, Cv, and Cw (see FIGS. 6(a) and 6(b)) of the lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8, respectively (see FIG. 5(a)).

[0063] In this way, by supporting each of the circumferentially extending portions Cu, Cv, Cw individually in the U-phase circumferential groove 83, the V-phase circumferential groove 84, and the W-phase circumferential groove 85, the circumferentially extending portions Cu, Cv, Cw can be arranged in an orderly manner relative to the coil holder 80 without shorting each other between different phases.

[0064] The U-phase circumferential groove 83, the V-phase circumferential groove 84, and the W-phase circumferential groove 85 extend in the circumferential direction of the cylindrical main body portion 81 and are provided around the entire circumference. The U-phase circumferential groove 83 is disposed on one axial side (upper side in the figure) of the cylindrical main body portion 81, the V-phase circumferential groove 84 is disposed in the axial center portion of the cylindrical main body portion 81, and the W-phase circumferential groove 85 is disposed on the other axial side (lower side in the figure) of the cylindrical main body portion 81. The U-phase circumferential groove 83 is disposed on the innermost side in the radial direction of the coil holder 80, the V-phase circumferential groove 84 is disposed in the radial center portion of the coil holder 80, and the W-phase circumferential groove 85 is disposed on the outermost side in the radial direction of the coil holder 80 (see FIGS. 4, 5, and 8).

[0065] In this manner, the U-phase circumferential groove 83, the V-phase circumferential groove 84, and the W-phase circumferential groove 85 are provided offset in the axial and radial directions of the coil holder 80 (the cylindrical main body portion 81). This reliably prevents the circumferentially extending portions Cu, Cv, and Cw from shorting out with each other.

[0066] Further, a first overhanging portion 83a is provided on one axial side (upper side in FIG. 8(a)) of the U-phase circumferential groove 83. The first overhanging portion 83a is provided extending in the circumferential direction of the coil holder 80, and partially covers the circumferential extending portion Cu (see FIGS. 6(a) and 6(b)) from one axial side of the stator 40 (see FIG. 4).

[0067] 5(b), the first overhanging portion 83a covers some of the terminal connection portions Nu of the U-phase extended portions 70u1-70u8 from one axial side of the stator 40. On the other hand, the first overhanging portion 83a is not provided on the bent portions Pu (four locations in total) of the U-phase extended portions 70u1, 70u2, 70u7, 70u8.

[0068] As a result, as shown in FIG. 5(b), when the coil holder 80 is viewed from one axial side of the stator 40, the bent portions Pu (four in total) in the U-phase lead-out portions 70u1, 70u2, 70u7, and 70u8 among the multiple bent portions Pu are visible.

[0069] Furthermore, a second overhanging portion 84a is provided on one axial side (upper side in FIG. 8(a)) of the V-phase circumferential groove 84. The second overhanging portion 84a is provided extending in the circumferential direction of the coil holder 80, and partially covers the circumferential extending portion Cv (see FIGS. 6(a) and 6(b)) from one axial side of the stator 40 (see FIG. 4).

[0070] 5(b), the second overhanging portion 84a covers a portion of the terminal connection portions Nv of the V-phase extended portions 70v1-70v8 from one axial side of the stator 40. On the other hand, the second overhanging portion 84a is not provided at the bent portions Pv (two in total) of the V-phase extended portions 70v1, 70v2.

[0071] As a result, as shown in FIG. 5(b), when the coil holder 80 is viewed from one axial side of the stator 40, the bent portions Pv (two in total) in the V-phase lead portions 70v1, 70v2 among the multiple bent portions Pv are visible.

[0072] Further, a third overhanging portion 85a is provided on one axial side (upper side in FIG. 8(a)) of the W-phase circumferential groove 85. The third overhanging portion 85a is provided extending in the circumferential direction of the coil holder 80, and partially covers the circumferential extending portion Cw (see FIGS. 6(a) and 6(b)) from one axial side of the stator 40 (see FIG. 4).

[0073] 5(b), the third overhanging portion 85a covers a portion of the terminal connection portions Nw of the W-phase extended portions 70w1-70w8 from one axial side of the stator 40. On the other hand, the third overhanging portion 85a is not provided at the bent portions Pw (two in total) of the W-phase extended portions 70w1, 70w2.

[0074] As a result, as shown in FIG. 5(b), when the coil holder 80 is viewed from one axial side of the stator 40, the bent portions Pw (two in total) in the W-phase lead-out portions 70w1, 70w2 among the multiple bent portions Pw are visible.

[0075] Here, the first, second, and third overhanging portions 83a, 84a, and 85a correspond to the covering walls in the present invention. In particular, by providing the first, second, and third overhanging portions 83a, 84a, and 85a at the terminal connection portions Nu, Nv, and Nw, respectively, the terminal connection portions Nu, Nv, and Nw are reliably prevented from shorting out with each other. This makes it possible to reliably connect the U-phase, V-phase, and W-phase power terminals Tu, Tv, and Tw to the terminal connection portions Nu, Nv, and Nw without causing a short circuit between different phases.

[0076] In order to reliably prevent short circuits between different phases, the first, second, and third overhanging portions 83a, 84a, and 85a may each be extended around the entire circumference of the coil holder 80. In this case, however, it becomes difficult to perform wiring work (such as work to form bent portions Pu, Pv, and Pw) on the coil holder 80 in all of the lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8. Therefore, in this embodiment, a total of eight bent portions Pu (four locations), Pv (two locations), and Pw (two locations) are made visible when the coil holder 80 is viewed from one axial side of the stator 40, as described above.

[0077] 5(b), of the terminal connection portions Nu, Nv, and Nw, the largest portion of the terminal connection portion Nu is hidden by the first overhanging portion 83a. That is, when viewed in the axial direction of the stator 40, the terminal connection portion Nu is least exposed. This reliably prevents the terminal connection portion Nu from shorting out (contacting) with the bearing holder 57 located above it (upper side in FIG. 3).

[0078] Next, a procedure for assembling brushless motor 10 formed as above, in particular a procedure for arranging some of U-phase, V-phase, and W-phase lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 in coil holder 80 will be described in detail with reference to the drawings.

[0079] Figures 9(a) and (b) are diagrams explaining the procedure for wiring the U-phase lead-out portion (part of one radial side) to the coil holder, Figures 10(a) and (b) are diagrams explaining the procedure for wiring the U-phase lead-out portion (part of the other radial side) to the coil holder, Figures 11(a) and (b) are diagrams explaining the procedure for wiring the V-phase lead-out portion (part of one radial side) to the coil holder, and Figures 12(a) and (b) are diagrams explaining the procedure for wiring the W-phase lead-out portion (part of one radial side) to the coil holder.

[0080] First, as shown in Figures 9(a) and (b), we will explain the procedure for arranging the U-phase lead-out portions 70u1, 70u2 (part of the U-phase lead-out portion) provided on one radial side of the stator 40 (the left side of Figure 5(b)) to the coil holder 80.

[0081] As indicated by arrow M1 in Fig. 9(a), U-phase lead-out portion 70u1 (see Fig. 4) drawn out in the axial direction of stator 40 is passed through a predetermined first recess 82. Specifically, U-phase lead-out portion 70u1 is passed through first recess 82 near one longitudinal side (the left side in Fig. 5(b)) of first overhanging portion 83a.

[0082] Next, as shown by arrow M2 in FIG. 9(b), U-phase extended portion 70u1 that has been passed through a predetermined first recess 82 is bent toward U-phase circumferential groove 83. At this time, U-phase extended portion 70u1 is visible from one axial side of stator 40 and is not obstructed by first overhanging portion 83a. Therefore, U-phase extended portion 70u1 can be easily bent along arc-shaped corner portion 82a. Then, the tip side (terminal connection portion Nu side) of U-phase extended portion 70u1 is arranged to be aligned with U-phase circumferential groove 83.

[0083] This completes the arrangement of the U-phase lead-out portion 70u1 into the U-phase circumferential groove 83, a circumferential extending portion Cu is formed along the U-phase circumferential groove 83, a bent portion Pu is formed in the portion corresponding to the arc-shaped corner portion 82a, and further, an axially extending portion Au is formed along the first recess 82.

[0084] 9(a), U-phase lead-out portion 70u2 drawn out in the axial direction of stator 40 is passed through a predetermined first recess 82. Specifically, U-phase lead-out portion 70u2 is passed through the first recess 82 that is adjacent to the first recess 82 on the right side in the figure with respect to the first recess 82 through which U-phase lead-out portion 70u1 passes.

[0085] Then, as shown by an arrow M4 in FIG. 9(b), the U-phase drawn-out portion 70u2 that has been passed through the predetermined first recess 82 is bent toward the U-phase circumferential groove 83. At this time, the U-phase drawn-out portion 70u2 is also visible from one axial side of the stator 40 and is not obstructed by the first overhanging portion 83a. Therefore, the U-phase drawn-out portion 70u2 can also be easily bent along the corresponding arc-shaped corner portion 82a. Then, the tip side (terminal connection portion Nu side) of the U-phase drawn-out portion 70u2 is arranged to be aligned with the U-phase circumferential groove 83. At this time, the U-phase drawn-out portion 70u2 is overlapped with the U-phase drawn-out portion 70u1 in the radial direction of the stator 40 (see FIG. 7(a)).

[0086] This completes the arrangement of the U-phase lead-out portion 70u2 into the U-phase circumferential groove 83, a circumferential extending portion Cu is formed along the U-phase circumferential groove 83, a bent portion Pu is formed in the portion corresponding to the arc-shaped corner portion 82a, and further, an axially extending portion Au is formed along the first recess 82.

[0087] Next, as shown in Figures 10(a) and (b), a procedure for arranging the U-phase lead-out portions 70u7, 70u8 (part of the U-phase lead-out portion) provided on the other radial side of the stator 40 (the right side of Figure 5(b)) to the coil holder 80 will be described.

[0088] As indicated by arrow M5 in Fig. 10(a), the U-phase lead-out portion 70u7 (see Fig. 4) drawn out in the axial direction of the stator 40 is passed through a predetermined first recess 82. Specifically, the U-phase lead-out portion 70u7 is passed through the first recess 82 near the other longitudinal side (the right side in Fig. 5(b)) of the first overhanging portion 83a.

[0089] Next, as shown by an arrow M6 in FIG. 10(b), the U-phase extended portion 70u7 that has been passed through a predetermined first recess 82 is bent toward the U-phase circumferential groove 83. At this time, the U-phase extended portion 70u7 is visible from one axial side of the stator 40 and is not obstructed by the first overhanging portion 83a. Therefore, the U-phase extended portion 70u7 can be easily bent along the arc-shaped corner portion 82a. Then, the tip side (terminal connection portion Nu side) of the U-phase extended portion 70u7 is arranged to be aligned with the U-phase circumferential groove 83.

[0090] This completes the arrangement of the U-phase lead-out portion 70u7 into the U-phase circumferential groove 83, a circumferential extending portion Cu is formed along the U-phase circumferential groove 83, a bent portion Pu is formed in the portion corresponding to the arc-shaped corner portion 82a, and further, an axially extending portion Au is formed along the first recess 82.

[0091] 10(a), the U-phase lead-out portion 70u8 drawn out in the axial direction of the stator 40 is passed through a predetermined first recess 82. Specifically, the U-phase lead-out portion 70u8 is passed through the first recess 82 that is adjacent to the first recess 82 on the left side in the figure with respect to the first recess 82 through which the U-phase lead-out portion 70u7 passes.

[0092] Then, as shown by an arrow M8 in FIG. 10(b), the U-phase lead-out portion 70u8 that has been passed through the predetermined first recess 82 is bent toward the U-phase circumferential groove 83. At this time, the U-phase lead-out portion 70u8 is also visible from one axial side of the stator 40 and is not obstructed by the first overhanging portion 83a. Therefore, the U-phase lead-out portion 70u8 can also be easily bent along the corresponding arc-shaped corner portion 82a. Then, the tip side (terminal connection portion Nu side) of the U-phase lead-out portion 70u8 is arranged to be aligned with the U-phase circumferential groove 83. At this time, the U-phase lead-out portion 70u8 is overlapped with the U-phase lead-out portion 70u7 in the radial direction of the stator 40 (see FIG. 7(a)).

[0093] This completes the arrangement of the U-phase lead-out portion 70u8 into the U-phase circumferential groove 83, a circumferential extending portion Cu is formed along the U-phase circumferential groove 83, a bent portion Pu is formed in the portion corresponding to the arc-shaped corner portion 82a, and further, an axially extending portion Au is formed along the first recess 82.

[0094] 11(a) and (b), the procedure for routing V-phase lead-out portions 70v1, 70v2 (parts of the V-phase lead-out portion) provided on one radial side of stator 40 (the left side in FIG. 5(b)) to coil holder 80 is similar to the procedure for routing U-phase lead-out portions 70u1, 70u2 shown in FIG. 9(a) and (b) to coil holder 80. Specifically, V-phase lead-out portion 70v1 is routed in the order indicated by arrows M9 and M10 in the figure, and V-phase lead-out portion 70v2 is routed in the order indicated by arrows M11 and M12 in the figure.

[0095] Note that the V-phase led-out portions 70v1, 70v2, which are to be arranged in the V-phase circumferential groove 84 later, are shifted radially outward from the U-phase led-out portions 70u1, 70u2, which are arranged in the U-phase circumferential groove 83 first. Therefore, when the V-phase led-out portions 70v1, 70v2 are arranged in the coil holder 80, the V-phase led-out portions 70v1, 70v2 do not interfere with the U-phase led-out portions 70u1, 70u2. This reliably prevents the two from being damaged due to interference with each other.

[0096] 12(a) and (b), the procedure for routing W-phase lead-out portions 70w1, 70w2 (parts of the W-phase lead-out portion) provided on one radial side of stator 40 (the left side in FIG. 5(b)) to coil holder 80 is similar to the procedure for routing U-phase lead-out portions 70u1, 70u2 shown in FIG. 9(a) and (b) to coil holder 80. Specifically, W-phase lead-out portion 70w1 is routed in the procedure shown by arrows M13 and M14 in the figure, and W-phase lead-out portion 70w2 is routed in the procedure shown by arrows M15 and M16 in the figure.

[0097] It should be noted that the W-phase led-out portions 70w1, 70w2, which are to be arranged in the W-phase circumferential groove 85 later, are shifted radially outward from the V-phase led-out portions 70v1, 70v2, which are arranged in the V-phase circumferential groove 84 first. Therefore, when the W-phase led-out portions 70w1, 70w2 are arranged in the coil holder 80, the W-phase led-out portions 70w1, 70w2 do not interfere with the V-phase led-out portions 70v1, 70v2. This reliably prevents the W-phase led-out portions 70w1, 70w2 from being damaged due to mutual interference.

[0098] Here, the U-phase, V-phase, and W-phase extended portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 do not have to be arranged in the order of U-phase, V-phase, and W-phase in the coil holder 80. For example, the U-phase, V-phase, and W-phase extended portions 70u1-70u4, 70v1-70v4, and 70w1-70w4 provided on one radial side of the stator 40 may be arranged first, and then the U-phase, V-phase, and W-phase extended portions 70u5-70u8, 70v5-70v8, and 70w5-70w8 provided on the other radial side of the stator 40 may be arranged.

[0099] As described above in detail, according to the present embodiment, brushless motor 10 includes stator 40 around which U-phase, V-phase, and W-phase coils 70 are wound, and rotor 50 that rotates relative to stator 40. U-phase, V-phase, and W-phase lead-out portions 70u1 to 70u8, 70v1 to 70v8, and 70w1 to 70w8 are led out to one axial side of stator 40. are provided, and the U-phase, V-phase, and W-phase lead-out portions 70u1-70u8, 70v1-70v8, 70w1-70w8 include axially extending portions Au, Av, and Aw extending in the axial direction of the stator 40, circumferentially extending portions Cu, Cv, and Cw extending in the circumferential direction of the stator 40, and bent portions Pu, Pv, and Pw provided between the axially extending portions Au, Av, and Aw and the circumferentially extending portions Cu, Cv, and Cw.

[0100] Further, a coil holder 80 is provided on one axial side of the stator 40, which holds the U-phase, V-phase, and W-phase lead-out portions 70u1-70u8, 70v1-70v8, 70w1-70w8, respectively. The coil holder 80 has a plurality of first recesses 82 arranged in a line in the circumferential direction of the coil holder 80 and supporting the axial extending portions Au, Av, and Aw, respectively, U-phase, V-phase, and W-phase circumferential grooves 83, 84, and 85 arranged in a line in the axial direction of the coil holder 80 and supporting the circumferential extending portions Cu, Cv, and Cw, respectively, and first, second, and third overhanging portions 83a, 84a, and 85a arranged extending in the circumferential direction of the coil holder 80 and partially covering the circumferential extending portions Cu, Cv, and Cw from one axial side of the stator 40.

[0101] Furthermore, when the coil holder 80 is viewed from one axial side of the stator 40, some of the multiple bent portions Pu, Pv, and Pw are visible.

[0102] This makes it possible to easily bend some of the U-phase, V-phase, and W-phase extended portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 that form the visible bent portions Pu, Pv, and Pw, improving the ease of arranging some of the U-phase, V-phase, and W-phase extended portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 into the coil holder 80. This makes it possible to improve the ease of assembly of the brushless motor 10.

[0103] Furthermore, according to this embodiment, terminal connection portions Nu, Nv, Nw are provided on the opposite side of the bent portions Pu, Pv, Pw in the longitudinal direction of the circumferential extending portions Cu, Cv, Cw, which protrude radially outward from the stator 40 and to which the U-phase, V-phase, and W-phase power supply terminals Tu, Tv, Tw are electrically connected, and the first, second, and third overhanging portions 83a, 84a, 85a cover portions of the terminal connection portions Nu, Nv, Nw from one axial side of the stator 40.

[0104] This makes it possible to reliably prevent the terminal connections Nu, Nv, Nw from shorting out with each other.

[0105] Furthermore, according to this embodiment, when the U-phase, V-phase, and W-phase lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 are viewed from one axial side of the stator 40, the U-phase, V-phase, and W-phase lead-out portions 70u1-70u8, 70v1-70v8, and 70w1-70w8 have mirror-symmetrical shapes about first, second, and third reference lines BP1, BP2, and BP3, which pass through the axis Cn of the stator 40 (see FIG. 7) and the centers of the terminal connection portions Nu, Nv, and Nw in the circumferential direction of the stator 40.

[0106] This allows the length dimensions of each pair of U-phase, V-phase, and W-phase lead-out sections 70u1-70u8, 70v1-70v8, and 70w1-70w8 to be as uniform as possible, thereby making it possible to achieve a good balance in the amount of current flowing through each of the U-phase, V-phase, and W-phase coils 70, and resulting in a brushless motor 10 with little rotational wobble.

[0107] Furthermore, according to the present embodiment, coils 70 for the U phase, V phase, and W phase wound around stator 40 are delta connected, eliminating the need for a coil or conductive member that forms a neutral point, which is required in star connection. This in turn simplifies the structure of brushless motor 10, making it smaller and lighter, and improving the ease of assembly of brushless motor 10.

[0108] Furthermore, according to this embodiment, coil 70 is formed from a flat wire having a rectangular cross section in a direction intersecting the longitudinal direction, so that coil 70 can be wound around stator 40 orderly and without gaps, thereby improving the space factor. This makes it possible to realize a brushless motor 10 that is compact yet capable of producing large output.

[0109] The present invention is not limited to the above-described embodiment, and various modifications are possible without departing from the spirit of the present invention. In the above-described embodiment, the brushless motor 10 as a motor device is applied to a drive source of an electric motorcycle or the like, but the present invention is not limited to this. For example, the brushless motor 10 can be applied to a drive source of small mobility devices such as an electric wheelchair or an electric push cart, a drive source of joints of an arm robot, or even a drive source of a power steering device.

[0110] In addition, in the above embodiment, the coil 70 is made of aluminum, but the present invention is not limited to this, and it is also possible to adopt, for example, a general-purpose coil made of cheaper brass or the like.

[0111] Furthermore, the material, shape, size, number, installation location, etc. of each component in the above-described embodiment may be arbitrary as long as it achieves the present invention, and is not limited to the above-described embodiment. [Explanation of symbols]

[0112] 10: brushless motor (motor device), 20: housing, 21: housing body, 21a: bottom wall portion, 21b: bearing mounting portion, 21c: seal mounting portion, 21d: cylindrical wall portion, 21e: cooling fin, 22: cover member, 22a: main cover portion, 22b: sub-cover portion, 23: polygonal wall portion, 23a: first side portion, 23b: second side portion, 23c: third side portion, 23d: fourth side portion, 23e: fifth side portion, 23f: sixth side portion, 24: drive connector, 24a: connector block, 25: convex portion, 25a: bottom wall, 25b: first side wall, 25c: second side wall, 25d: connector fixing portion ,26: Connector for board, 26a: Fixing plate portion, 26b: Outer connection portion, 30: Motor unit, 40: Stator, 42: Wire harness for board, 43: Controller side connector portion, 44: Board side connector portion, 45: Engagement recess, 50: Rotor, 51: Rotor body, 52: Rotating shaft, 53: Magnet, 54: Sensor magnet, 55: Sensor board, 56: Rotation sensor, 57: Bearing holder, 57a: Retaining tube, 57b: Support plate, 57c: Support column, 58: Board side connection portion, 60: Split core, 61: Teeth, 62: Insulator, 70: Coil, 70 u1 to 70u8: U-phase lead-out portion (coil lead-out portion), 70v1 to 70v8: V-phase lead-out portion (coil lead-out portion), 70w1 to 70w8: W-phase lead-out portion (coil lead-out portion), 80: coil holder, 81: cylindrical main body portion, 81a: engagement protrusion portion, 82: first recess (first support portion), 82a: arc-shaped corner portion, 83: U-phase circumferential groove (second support portion), 83a: first overhang portion (covering wall), 84: V-phase circumferential groove (second support portion), 84a: second overhang portion (covering wall), 85: W-phase circumferential groove (second support portion), 85a: third overhang portion (covering wall), Au to Aw: axial extension portion, B1: first fixing bolt ,B2: Second fixing bolt,BB1: First ball bearing,BB2: Second ball bearing,BP1: First reference line (reference line),BP2: Second reference line (reference line),BP3: Third reference line (reference line),BT: Fixing bolt,CU: Controller,Cn: Shaft center,Cu~Cw: Circumferential extension,Eu: U-phase wire,Eu: W-phase wire,Ev: V-phase wire,Ew: W-phase wire,LS: Lip seal,Nu~Nw: Terminal connection,Pu~Pw: Bend,S1: First screw,S2: Second screw,SE: Board wire,SP: Connection space,Tu: U-phase power terminal (power terminal),Tv: V-phase power terminal (power terminal), Tw: W-phase power terminal (power terminal),

Claims

1. A stator wound with a plurality of coils; a rotor that rotates relative to the stator; A motor device having Each of the coils is provided with a coil lead-out portion that is led out to one axial side of the stator, The coil lead-out portion is an axially extending portion extending in an axial direction of the stator; a circumferential extending portion extending in a circumferential direction of the stator; a bent portion provided between the axially extending portion and the circumferentially extending portion; It is equipped with a coil holder that holds each of the coil lead-out portions is provided on one axial side of the stator; The coil holder includes: a plurality of first support portions arranged side by side in a circumferential direction of the coil holder and supporting the plurality of axially extending portions, respectively; a plurality of second support portions arranged side by side in an axial direction of the coil holder and supporting the plurality of circumferentially extending portions, respectively; a covering wall provided to extend in a circumferential direction of the coil holder and partially covering the plurality of circumferential extending portions from one axial side of the stator; It has When the coil holder is viewed from one axial side of the stator, some of the plurality of bent portions are visible, a terminal connection portion that protrudes radially outward from the stator and is electrically connected to a power supply terminal, the terminal connection portion being provided on a side opposite to the bent portion in the longitudinal direction of the circumferential extending portion; The covering wall covers a part of the terminal connection portion from one axial side of the stator. Motor device.

2. 2. The motor device according to claim 1, the coil lead-out portions are provided corresponding to a U-phase, a V-phase, and a W-phase, and when the coil lead-out portions are viewed from one axial side of the stator, each of the coil lead-out portions has a mirror-symmetric shape with respect to a reference line that passes through an axis of the stator and a center of the terminal connection portion in the circumferential direction of the stator. Motor device.

3. The coils wound around the stator are delta-connected. The motor device according to claim 1 or 2.

4. The coil is formed of a rectangular wire having a rectangular cross-sectional shape in a direction intersecting the longitudinal direction. The motor device according to any one of claims 1 to 3.

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