Gear motor

Abstract

To provide a gear motor capable of reducing the weight of a shaft.SOLUTION: A gear motor with a motor and a speed reducer includes a shaft body in which a rotor shaft rotated by the motor and an input shaft of a speed reducer are integrated, and the shaft body is formed by integrating a resin portion made of a resin-based material and a metal portion made of a metal-based material.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a gear motor. [Background technology]

[0002] Patent Document 1 discloses a gear motor including a motor and a reducer. This gear motor includes a shaft body in which a rotor shaft rotated by the motor and an input shaft of the reducer are integrated. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-97364 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the shaft body of Patent Document 1, both the input shaft and the rotor shaft are integrally formed from metal. The inventors of the present application recognized that there is room for improvement in the technology disclosed in Patent Document 1 in terms of reducing the weight of the shaft body.

[0005] An object of the present disclosure is to provide a gear motor that can reduce the weight of the shaft body. [Means for solving the problem]

[0006] The gear motor of the present disclosure is a gear motor equipped with a motor and a reducer, and includes a shaft body in which a rotor shaft rotated by the motor and an input shaft of the reducer are integrated, and the shaft body is configured to be integrated with a resin portion made of a resin-based material and a metal portion made of a metal-based material. Effect of the Invention

[0007] According to the present disclosure, the weight of the shaft body can be reduced. [Brief description of the drawings]

[0008] [Figure 1] 1 is a side cross-sectional view of a gear motor according to a first embodiment. [Diagram 2] FIG. 2 is a perspective view showing a shaft body of the first embodiment together with the surrounding structure. [Diagram 3] FIG. 2 is a side cross-sectional view showing the shaft body of the first embodiment together with the surrounding structure. [Figure 4] FIG. 4 is a cross-sectional view of the AA end of FIG. [Diagram 5] 4 is a view of the shaft body as viewed from arrow B in FIG. 3. [Figure 6] 5A to 5C are views for explaining a molding method of the shaft body of the first embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment will be described. The same components are given the same reference numerals, and duplicated explanations will be omitted. In each drawing, for the sake of convenience, components are omitted, enlarged, or reduced as appropriate. The drawings should be viewed according to the orientation of the reference numerals.

[0010] Please refer to Fig. 1. A gear motor 10 connects a first mating member 12 and a second mating member 14. The gear motor 10 can rotate the second mating member 14 relative to the first mating member 12. The gear motor 10 of this embodiment is incorporated into a joint of an industrial robot. The first and second mating members 12 and 14 of this embodiment are formed by either a base member or an arm member of a multi-joint arm.

[0011] The gear motor 10 includes a motor 16, a rotor shaft 18 rotated by the motor 16, a reducer 20 that reduces the rotation of the rotor shaft 18, and a shaft body 22 in which the rotor shaft 18 and an input shaft 42 of the reducer 20 are integrated. In addition, the gear motor 10 includes a housing 24 that accommodates a speed reduction mechanism 44 of the reducer 20 and the motor 16, a detector 26 that detects the rotation of the shaft body 22, a brake 28 that brakes the shaft body 22, and a plurality of bearings 30, 32, 34 arranged on the outer periphery of the shaft body 22. The first mating member 12 is integrated with the housing 24 using screws or the like, and the second mating member 14 is integrated with a carrier 46 of the reducer 20 using screws or the like.

[0012] Hereinafter, the direction along the rotation center line CL of the shaft body 22 will be referred to as the axial direction X, and the circumferential direction and radial direction of a circle centered on the rotation center line CL will be referred to as the "circumferential direction" and the "radial direction", respectively. Also, the side from the motor 16 toward the reducer 20 in the axial direction X (the left side in FIG. 1) will be referred to as the load side, and the opposite side in the axial direction X (the right side in FIG. 1) will be referred to as the anti-load side.

[0013] The motor 16 includes a stator 36 fixed to a motor housing 60 of the housing 24, and a rotor 38 that rotates integrally with the rotor shaft 18. The rotor 38 in this embodiment is a permanent magnet rotor. The rotor 38 includes a rotor core 40 formed of a laminated body of multiple metal plates 40a (e.g., electromagnetic steel plates, etc.), and permanent magnets (not shown) arranged in the slots of the rotor core 40. The rotor shaft 18 passes through the motor 16 in the axial direction X.

[0014] The reduction gear 20 includes an input shaft 42 to which the rotation of the rotor shaft 18 is input, and a reduction mechanism 44 that reduces the rotation of the input shaft 42. In addition, the reduction gear 20 includes a carrier 46 that is disposed on the axial load side of the reduction mechanism 44, a reduction gear housing 48 that accommodates the reduction mechanism 44, and an output member 50 that takes out the reduced rotation from the reduction mechanism 44.

[0015] The reduction mechanism 44 of this embodiment is a flexible mesh type gear mechanism in which the external gear 52 is flexibly deformed by the input shaft 42 to rotate one of the external gear 52 and the internal gear 56, and the rotation component is extracted by the output member 50. The reduction mechanism 44 of this embodiment is a cylindrical flexible mesh type gear mechanism using a first internal gear 54 whose relative rotation with respect to the reducer housing 48 is restricted, and a second internal gear 56 that is rotatable relative to the reducer housing 48.

[0016] The input shaft 42 is equipped with a gear drive unit 58 that drives a gear (external gear 52) of the reduction mechanism 44 when the input shaft 42 rotates. The gear drive unit 58 of the input shaft 42 used in the flexible meshing gear mechanism has an elliptical shape in a cross section perpendicular to the axial direction X. The gear drive unit 58 is provided at a position radially overlapping with the gear 52 of the reduction mechanism 44 to be driven.

[0017] The reduction mechanism 44 includes an external gear 52 arranged on the outer periphery of the input shaft 42, and first and second internal gears 54, 56 that mesh with the external gear 52. The external gear 52 is rotatably supported by the input shaft 42 via a gear bearing 30 that is arranged between a gear drive portion 58 of the input shaft 42 and the external gear 52. The external gear 52 of this embodiment is flexible, and is flexibly deformed to form an elliptical shape that matches the gear drive portion 58 when the input shaft 42 rotates.

[0018] The first internal gear 54 is disposed on the anti-load side. The second internal gear 56 is disposed on the load side. The first internal gear 54 has a number of internal teeth different from the number of external teeth of the external gear 52, and the second internal gear 56 has a number of internal teeth equal to the number of external teeth of the external gear 52. In the reduction gear mechanism 44 of this embodiment, the external gear 52 rotates together with the second internal gear 56 at a speed according to the difference in the number of teeth between the external gear 52 and the first internal gear 54 every time the input shaft 42 rotates once.

[0019] The reducer housing 48 of this embodiment includes a first housing member 48A that also serves as the first internal gear 54, and a second housing member 48B that is disposed radially outward from the second internal gear 56. The first housing member 48A and the second housing member 48B are integrated with each other by screws or the like. A main bearing 59 is disposed between the reducer housing 48 and the second internal gear 56.

[0020] The output member 50 of this embodiment is the carrier 46, and outputs the rotation extracted from the reduction mechanism 44 to the second mating member 14. Alternatively, the output member 50 may be a reduction gear housing 48.

[0021] The housing 24 includes the aforementioned reducer housing 48 that houses the speed reduction mechanism 44, and a motor housing 60 that houses the motor 16. The reducer housing 48 is integrated with the motor housing 60 using bolts or the like.

[0022] The detector 26 of this embodiment is a rotary encoder. The detector 26 includes a detected member 62 that can rotate integrally with the shaft body 22, and a sensor 64 that can detect the detected member 62. The detected member 62 is an encoder disk, and the sensor 64 is, for example, an optical sensor or a magnetic sensor. The detector 26 can detect the rotation of the shaft body 22 by detecting the detected member 62 with the sensor 64. The detected member 62 of this embodiment is disposed at the anti-load side end 22a of the shaft body 22. The sensor 64 is disposed at a position facing the detected member 62 in the axial direction X. The sensor 64 of this embodiment is mounted on a circuit board 66 used to control the motor 16. The circuit board 66 is attached to the motor housing 60 via a board holder 68.

[0023] The brake 28 is provided on the load side of the motor 16. The brake 28 is provided between the motor 16 and the reducer 20. The brake 28 includes a brake rotor 70 attached to the shaft 22, a brake mechanism 72 that brakes the brake rotor 70, and a brake body 74 on which the brake mechanism 72 is mounted. The brake 28 in this embodiment is a disc brake. The brake mechanism 72 is, for example, a combination of a coil and a spring. The brake mechanism 72 sandwiches the brake rotor 70 between a plurality of friction members 76, and is capable of braking the shaft 22 together with the brake rotor 70 by friction of the friction members 76.

[0024] The multiple bearings 30, 32, 34 include a gear bearing 30 arranged between the shaft body 22 and a gear (external gear 52) of the reduction mechanism 44 driven by a gear drive unit 58 of the shaft body 22. In addition, the multiple bearings 30, 32, 34 include input bearings 32, 34 provided at intervals in the axial direction X from the gear bearing 30. The gear bearings 30 of this embodiment are individually provided corresponding to the multiple internal gears 54, 56 and arranged inside the corresponding internal gears 54, 56. The input bearings 32, 34 of this embodiment include a first input bearing 32 provided on the anti-load side in the axial direction from the gear bearing 30 and a second input bearing 34 provided on the load side in the axial direction from the gear bearing 30.

[0025] The gear bearing 30 of this embodiment is a so-called vibrator bearing. The gear bearing 30 is a rolling bearing such as a roller bearing. The gear bearing 30 includes a plurality of rolling elements 78 such as rollers, and a retainer 80 that holds the plurality of rolling elements 78. The gear bearing 30 of this embodiment does not include a dedicated inner ring. Instead, the outer periphery of the shaft body 22 (gear bearing arrangement portion 90 described later) functions as the inner ring. Like the inner ring, the gear bearing 30 does not include a dedicated outer ring, and the inner periphery of the external gear 52 functions as the outer ring. In addition, the gear bearing 30 may include dedicated outer and inner rings.

[0026] The first input bearing 32 is disposed between the housing 24 and the shaft body 22. The second input bearing 34 is disposed between the carrier 46 and the shaft body 22. The first and second input bearings 34 are rolling bearings such as ball bearings.

[0027] Please refer to Figures 2 and 3. Figure 2 shows the rotor 38 in a schematic manner. For ease of explanation, a dot pattern is applied to a metal portion 106 in Figure 2, which will be described later. The shaft body 22 has a hollow portion 82 penetrating the shaft body 22 in the axial direction X. The shaft body 22 has a detector arrangement portion 84 in which a detection target member 62, which is a component of the detector 26, is arranged, and a rotor arrangement portion 86 in which the rotor 38 is arranged. In addition, the shaft body 22 has a brake arrangement portion 88 in which a brake rotor 70, which is a component of the brake 28, is arranged, and a plurality of bearing arrangement portions 90, 92, 94 in which bearings 30, 32, 34 are arranged.

[0028] In this embodiment, the detector arrangement portion 84 is provided at the anti-load side end portion 22a of the shaft body 22. The rotor arrangement portion 86 and the brake arrangement portion 88 are provided on the outer periphery of the portion of the shaft body 22 that will become the rotor shaft 18. The bearing arrangement portions 90, 92, 94 are provided on the outer periphery of the portion of the shaft body 22 that will become the input shaft 42.

[0029] The brake arrangement portion 88 has a plurality of protrusions 88a spaced apart in the circumferential direction. The plurality of protrusions 88a form a male spline. The brake rotor 70 has a female spline 70a provided on the inner periphery of the brake rotor 70. The brake rotor 70 is fixed to the brake arrangement portion 88 so as to be movable in the axial direction X by fitting the female spline 70a into the male spline formed by the plurality of protrusions 88a. The means for fixing the brake rotor 70 to the brake arrangement portion 88 is not particularly limited, and for example, a fitting involving a press fit without using a spline may be used.

[0030] The bearing arrangements 90, 92, 94 include a gear bearing arrangement 90 corresponding to the gear bearing 30, a first input bearing arrangement 92 corresponding to the first input bearing 32, and a second input bearing arrangement 94 corresponding to the second input bearing 34. In the bearing arrangements 90, 92, 94, the bearings 30, 32, 34 corresponding to the bearing arrangements 90, 92, 94 are arranged.

[0031] The gear bearing arrangement portion 90 is provided on the outer periphery of the gear drive portion 58 of the shaft body 22. The gear bearing arrangement portion 90 of this embodiment has a rolling surface 91 on which the rolling elements 78 of the gear bearing 30 roll. The input bearing arrangement portions 92, 94 are provided at positions shifted in the axial direction X with respect to the gear bearing 30. The inner ring of the first input bearing 32 is arranged in the first input bearing arrangement portion 92. The inner ring of the first input bearing 32 is fixed to the first input bearing arrangement portion 92 by fitting with press fitting or the like. The inner ring of the second input bearing 34 is arranged in the second input bearing arrangement portion 94. The inner ring of the second input bearing 34 is fixed to the second input bearing arrangement portion 94 by fitting with press fitting or the like.

[0032] The shaft body 22 includes a groove-shaped retaining ring arrangement portion 98 in which a retaining ring 96 is arranged. The retaining ring 96 restricts axial movement of an inner ring of the first input bearing 32. The retaining ring arrangement portion 98 is provided on the axial load side of the first input bearing arrangement portion 92.

[0033] The shaft body 22 includes a shaft main body portion 100 that extends from inside the motor 16 to inside the reducer 20, and an input shaft constituent portion 102 that is disposed on the outer periphery of the shaft main body portion 100 within the reducer 20. The shaft main body portion 100 is continuous over the range from the anti-load side end portion 22a to the load side end portion 22b of the shaft body 22. A detector arrangement portion 84, a rotor arrangement portion 86, and a brake arrangement portion 88 are provided on the shaft main body portion 100. The input shaft constituent portion 102 constitutes the outer periphery of the input shaft 42. The input shaft constituent portion 102 is provided with a plurality of bearing arrangement portions 90, 92, 94.

[0034] The shaft body 22 is configured by integrating a resin portion 104 made of a resin-based material with a metal portion 106 made of a metal-based material. The resin-based material here refers to a material mainly made of resin. The resin used here is, for example, general-purpose engineering plastics, special engineering plastics, etc. In the case of general-purpose engineering plastics, for example, polyamide (for example, PA46), polyacetal, etc. are used. The resin-based material also includes a composite material made of a resin as a main material and other materials. The composite material is, for example, carbon fiber reinforced resin, glass fiber reinforced resin, etc. The metal-based material here refers to a material mainly made of metal. The metal used here is, for example, iron-based materials such as cast iron and steel, and aluminum-based materials such as aluminum alloys.

[0035] In general, the density of resin is smaller than that of metal. The density [kg / m 3 ] is the density [kg / m 3 ] can also be said to be smaller than

[0036] Furthermore, the wear resistance of metals is generally lower than that of resins. It can also be said that the specific wear rate of the metal-based material constituting the metal portion 106 is lower than the specific wear rate of the resin-based material constituting the resin portion 104. The specific wear rate here can be obtained by a wear test in which another mating member is slid against the target portion under consideration. This wear test is performed by measuring the wear rate when a mating member is slid on the sliding surface of a sample cut out from the target portion under consideration. Specific wear rate [mm 2 / kgf] is the load applied perpendicularly to the sliding surface [kgf], the sliding distance when the counter part is slid with that load applied to the sliding surface [mm], and the amount of wear of the sample due to that sliding [mm 3 [] is used to express the specific wear rate by the following formula (1). The specific wear rate of the metal part 106 and the specific wear rate of the resin part 104 are obtained by a wear test carried out under the same sliding conditions. "The same sliding conditions" means that the surface roughness of the sliding surface of the sample and the mating member, the material of the mating member are the same, and the lubrication conditions such as the presence or absence of a lubricant, its composition, etc. are the same. Specific wear rate = wear rate / (sliding distance x load) (1)

[0037] The resin portion 104 is an injection-molded product that can be obtained by injection molding. More specifically, the resin portion 104 is a part of an insert-molded product that can be obtained by insert molding using the metal portion 106 as an insert product, as described below. The metal portion 106 is a metal-processed product that can be obtained by metal processing such as cutting and casting.

[0038] Resin portion 104 constitutes shaft body portion 100 of shaft body 22. Similar to shaft body portion 100, resin portion 104 constitutes detector arrangement portion 84, rotor arrangement portion 86, and brake arrangement portion 88. Resin portion 104 constitutes the portions of shaft body 22 other than metal portion 106.

[0039] The metal portion 106 constitutes the outer circumferential portion of the shaft body 22 in the reducer 20. It can also be said that the metal portion 106 constitutes the input shaft configuration portion 102 of the shaft body 22. The metal portion 106 constitutes at least the outer circumferential portion of the gear drive portion 58, that is, the gear bearing arrangement portion 90. The rolling surface 91 of the gear bearing arrangement portion 90 is constituted by the metal portion 106. In addition to this, the metal portion 106 of this embodiment also constitutes a pair of input bearing arrangement portions 92, 94. The metal portion 106 constitutes the bearing arrangement portions 90, 92, 94 in which the bearings 30, 32, 34 used in the reducer 20 are arranged. The metal portion 106 constitutes the outer circumferential portion of the shaft body 22 in the axial range from the first input bearing arrangement portion 92 to the second input bearing arrangement portion 94.

[0040] The metal portion 106, the rotor 38, and the detection target member 62 which is a component 108 of the detector 26 are integrated into the resin portion 104 by insert molding. The shaft body 22 can also be said to be an integrally molded product which is integrated with the resin portion 104 by insert molding, with the metal portion 106, the rotor 38, and the component 108 serving as insert parts.

[0041] When the rotor 38 is integrated with the resin portion 104 by insert molding, a part of the resin portion 104 can be inserted into the minute gaps between the multiple metal plates 40a. These gaps are formed between the multiple metal plates 40a in the inner periphery of the rotor core 40. This can improve the bonding strength between the rotor core 40 and the resin portion 104 in the axial direction X.

[0042] Please refer to Figures 2 to 4. The metal part 106 has an outer cylindrical part 110 that constitutes the outer peripheral part of the input shaft 42. The bearing arrangement parts 90, 92, and 94 described above are provided on the outer peripheral part of the outer cylindrical part 110.

[0043] The resin portion 104 includes an inner cylindrical portion 112 disposed inside an outer cylindrical portion 110. The inner cylindrical portion 112 is cylindrical as a whole. The outer cylindrical portion 110 and the inner cylindrical portion 112 form a single cylindrical portion of the shaft body 22 that has a thickness in the radial direction.

[0044] The outer cylindrical portion 110 has metal protrusions 114 provided on an inner circumferential portion of the outer cylindrical portion 110 and protruding radially inward. In this embodiment, a plurality of metal protrusions 114 are provided at intervals in the circumferential direction. In this embodiment, the metal protrusions 114 are ridges extending in the axial direction X.

[0045] The inner cylindrical portion 112 has resin recesses 118 into which the metal protrusions 114 fit. The resin recesses 118 are recessed from the outer circumferential portion of the inner cylindrical portion 112 toward the inside in the radial direction. The resin recesses 118 are individually provided corresponding to the metal protrusions 114, and a plurality of the resin recesses 118 are provided at intervals in the circumferential direction. The resin recesses 118 in this embodiment are groove-shaped extending in the axial direction, and the metal protrusions 114, which are protrusions, fit into the entire axial range.

[0046] In this embodiment, the resin recess 118 forms a through hole that penetrates the inner cylindrical portion 112 in the radial direction, and the metal protrusion 114 penetrates the resin recess 118 in the radial direction. As a result, the inner peripheral side portion of the metal protrusion 114 is exposed to the hollow portion 82 of the shaft body 22 and forms the inner peripheral portion of the hollow portion 82. In this embodiment, the inner peripheral surface of the metal protrusion 114 and the inner peripheral surface of the inner cylindrical portion 112 are provided so as to be flush with each other. As a result, the metal protrusion 114 and the inner cylindrical portion 112 form a smoothly continuous inner peripheral surface of the hollow portion 82.

[0047] Please refer to Fig. 5. The resin portion 104 of this embodiment includes a misalignment prevention portion 120 that prevents misalignment by coming into contact with a component 108 of the detector 26. The misalignment prevention portion 120 of this embodiment is a protrusion provided on the detector arrangement portion 84. The misalignment prevention portion 120 of this embodiment can prevent misalignment in the circumferential direction by coming into contact with the component 108 in the circumferential direction. In addition, the misalignment prevention portion 120 may prevent misalignment in the axial direction X by coming into contact with the component 108 on the anti-load side in the axial direction.

[0048] 6(a), an example of a method for insert molding the shaft body 22 using a molding device 130 will be described.

[0049] First, the molding device 130 will be described. The molding device 130 includes a plurality of molding dies 134A, 134B that form a cavity 132 having a shape corresponding to the shaft body 22. The plurality of molding dies 134A, 134B include a first molding die 134A that molds the outer periphery of the resin portion 104, and a second molding die 134B that can mold the inner periphery of the resin portion 104. The number of molding dies 134A, 134B is not particularly limited, and may be three or more.

[0050] Next, the insert molding method will be described. First, as shown in Fig. 6(a), a plurality of molding dies 134A, 134B are closed to form a cavity 132 for molding the shaft body 22. At this time, the metal part 106, rotor 38, and components 108 of the detector 26 that will be the insert parts are placed in advance in the molding dies 134A, 134B.

[0051] 6(b), molten resin 136 is poured into cavity 132 and then cured. This allows for the production of shaft body 22 in which resin portion 104 and insert part (metal portion 106, etc.) are integrated.

[0052] 6(c), the multiple molding dies 134A, 134B are opened to remove the molded product, that is, the shaft body 22. At this time, for example, the first molding die 134A is moved in a direction Pa toward the load side (upper side in the figure) to open the mold, and the shaft body 22 is moved in the direction Pa to remove it from the second molding die 134B.

[0053] The effects of the above gear motor 10 will now be described.

[0054] The shaft body 22 is formed by integrating the resin portion 104 and the metal portion 106. Therefore, the weight of the shaft body 22 can be reduced compared to a case where the shaft body 22 is formed only by the metal portion 106.

[0055] In general, resin molding such as injection molding is more advantageous in terms of manufacturing cost and manufacturing time than metal processing such as cutting. A part of the shaft body 22 is formed of the resin portion 104. Therefore, according to this embodiment, it is possible to reduce the manufacturing cost and shorten the manufacturing time compared to the case where the shaft body 22 is formed only of the metal portion 106.

[0056] When metal processing is performed using a cutting machine such as a lathe, the workpiece is cut while being held in a chuck. In this case, process variations occur in which the processing conditions change for each processing process. The processing conditions here include, for example, the dimensions of the workpiece and the chucking method (the chucking position relative to the workpiece, etc.). The process variations during metal processing result in large variations in the dimensional accuracy of the molded product.

[0057] In contrast, when the resin portion 104 is obtained by injection molding, the shape of the mold is transferred to the resin portion 104. Therefore, if the dimensional accuracy of the mold is ensured, the dimensional accuracy of the resin portion 104 will be about the same as that of the mold, and no process variation occurs as in metal processing. Therefore, according to this embodiment, the dimensional accuracy of a part of the shaft body 22 (the resin portion 104) can be easily ensured compared to the case where the shaft body 22 is formed only from the metal portion 106.

[0058] When the reduction mechanism 44 operates, a large load acts on the outer circumferential portion of the shaft body 22 in the reducer 20. More specifically, a bending force is input as a large load from the reduction mechanism 44 to the outer circumferential portion (gear bearing arrangement portion 90) of the shaft body 22. At the same time, a reaction force to the bending force acts on the input bearing arrangement portions 92 and 94 of the shaft body 22 from the input bearings 32 and 34. As such, a large load acts on the outer circumferential portion (bearing arrangement portions 90, 92, 94) of the shaft body 22 in the reducer 20, and therefore the shaft body 22 is required to have the strength to withstand the large load.

[0059] Metal portion 106 is disposed on the outer periphery of shaft main body 100 within reducer 20. Therefore, the above-mentioned large load can be borne by metal portion 106. Therefore, metal portion 106 ensures durability in areas where strength is required, while resin portion 104 can reduce the weight of shaft body 22.

[0060] In the shaft body 22, the bearing arrangement sections 90, 92, and 94 to which a large load is input are formed by the metal portion 106. Therefore, the metal portion 106 ensures durability in areas where strength is particularly required, while the resin portion 104 makes it possible to reduce the weight of the shaft body 22.

[0061] Wear resistance is required for the rolling surface 91 on which the rolling elements 78 roll. In the shaft body 22, the portion requiring such wear resistance is formed by the metal portion 106. Therefore, the wear resistance of the rolling surface 91 is ensured by the metal portion 106, while the weight of the shaft body 22 can be reduced by the resin portion 104.

[0062] The resin portion 104 constitutes the detector arrangement portion 84, the rotor arrangement portion 86, and the brake arrangement portion 88. These are less likely to be subjected to a heavy load than the portion that becomes the input shaft 42 of the speed reducer 20. By forming these portions, which are less likely to be subjected to a heavy load, out of the resin portion 104, it is possible to rationally reduce the weight.

[0063] The resin portion 104 constitutes the brake arrangement portion 88 having the multiple protrusions 88a. Therefore, the processing cost can be reduced compared to the case where the multiple protrusions 88a are formed in the metal portion 106 by cutting or the like.

[0064] The outer cylindrical portion 110 of the metal portion 106 has a metal convex portion 114, and the inner cylindrical portion 112 of the resin portion 104 has a resin concave portion 118 into which the metal convex portion 114 fits. The metal convex portion 114 and the resin concave portion 118 can increase the contact area between the metal portion 106 and the resin portion 104 in the circumferential and axial directions. As a result, the bonding strength between the metal portion 106 and the resin portion 104 can be improved.

[0065] The metal portion 106, the rotor 38, and the components 108 of the detector 26 are integrated into the resin portion 104 by insert molding. Therefore, when integrating these components with the resin portion 104, it is not necessary to assemble these components with the resin portion 104. Furthermore, it is possible to eliminate the effects of assembly variations that occur during assembly, and it becomes easier to ensure positional accuracy regarding the relative positions of these components and the resin portion 104.

[0066] When assembly work of the shaft body 22 and the rotor 38 is required, processing is required to ensure high dimensional accuracy for the inner peripheral portion of the rotor 38 in order to ensure the positional accuracy of the rotor 38. In contrast, when insert molding is used, assembly work is not required, and therefore there is an advantage that processing to ensure the dimensional accuracy of the rotor 38 can be eliminated.

[0067] Other variations of each component are described.

[0068] There is no particular limitation on the use of the gear motor 10. For example, the gear motor 10 may be used in an automatic guided vehicle such as an AGV, other than an industrial robot.

[0069] The type of motor 16 is not particularly limited. For example, the motor 16 may be a permanent magnet motor using permanent magnets as in the embodiment, or an induction motor, reluctance motor, or the like. The rotor 38 may be a squirrel-cage rotor, a wound rotor, or the like. In either case, the rotor 38 may include a rotor core 40 made of laminated bodies. Alternatively, the rotor core 40 may be formed of a metal bushing. Alternatively, the rotor 38 may be a coreless rotor without a rotor core 40.

[0070] A specific example of the reduction mechanism 44 is not particularly limited. In addition to the flexible meshing gear mechanism, the reduction mechanism 44 may be, for example, an eccentric oscillating gear mechanism, a planetary gear mechanism, an orthogonal shaft gear mechanism, a parallel shaft gear mechanism, or the like. In the case of a flexible meshing gear mechanism, a specific example is not particularly limited. In addition to a cylindrical type, for example, a cup type or a top hat type may be used. When the reduction mechanism 44 is an eccentric oscillating gear mechanism, the gear drive portion 58 of the shaft body 22 is formed by an eccentric portion that is eccentric with respect to the center line of rotation.

[0071] The gear motor 10 does not necessarily have to include the detector 26. The detector 26 is not limited to a rotation detector, and may be, for example, a pressure detector, a temperature detector, etc. When the detector 26 constitutes a rotation detector, the specific example is not particularly limited, and may be a Hall IC, etc. The component 108 of the detector 26 arranged in the detector arrangement portion 84 of the shaft body 22 is also not particularly limited.

[0072] The gear motor 10 does not necessarily have to include the brake 28. A specific example of the brake 28 is not limited to a disk brake, and may be, for example, a drum brake. The position of the brake 28 is not particularly limited. For example, the brake 28 may be disposed on the anti-load side of the motor 16.

[0073] An example has been described in which resin portion 104 constitutes shaft main body 100, and metal portion 106 is disposed on the outer periphery of shaft main body 100 within reducer 20. Alternatively, metal portion 106 may constitute shaft main body 100, and resin portion 104 may be disposed on the outer periphery of shaft main body 100 within reducer 20. Alternatively, rotor shaft 18 may be constituted by one of resin portion 104 and metal portion 106, and input shaft 42 may be constituted by the other of them. In any case, shaft body 22 may have a configuration in which resin portion 104 and metal portion 106 are integrated, and the specific positions of each portion 104, 106 are not particularly limited.

[0074] The example has been described in which the metal portion 106 constitutes all of the multiple bearing arrangement portions 90, 92, and 94. Alternatively, the metal portion 106 may constitute only one of them. Alternatively, the metal portion 106 may be disposed on the outer circumferential portion of the shaft main body portion 100 within the reducer 20 at a location other than the bearing arrangement portions 90, 92, and 94.

[0075] The gear bearing arrangement portion 90 does not have to form the rolling surface 91. This assumes, for example, that the gear bearing 30 has a dedicated inner ring, and the inner ring of the gear bearing 30 is arranged in the gear bearing arrangement portion 90. Alternatively, the input bearing arrangement portions 92, 94 may form the rolling surfaces on which the rolling elements of the input bearings 32, 34 roll.

[0076] In the above embodiment, the detector mounting portion 84, the rotor mounting portion 86, and the brake mounting portion 88 of the shaft body 22 are made of the resin portion 104. However, one or all of these may be made of a metal portion 106.

[0077] The outer cylindrical portion 110 does not have to include the metal convex portion 114, and the inner cylindrical portion 112 does not have to include the resin concave portion 118. The number of the metal convex portion 114 and the resin concave portion 118 is not particularly limited. For example, there may be only one each of the metal convex portion 114 and the resin concave portion 118.

[0078] Although an example has been described in which the outer cylindrical portion 110 of the metal portion 106 constitutes the outer circumferential portion of the input shaft 42, its position on the shaft body 22 is not particularly limited. The outer cylindrical portion 110 may constitute the outer circumferential portion of the rotor shaft 18, for example.

[0079] The resin recess 118 may be configured as a bottomed hole that does not radially penetrate the inner cylindrical portion 112. This assumes, for example, a case in which the resin recess 118 is configured as a bottomed hole having a bottom on the radially inner side.

[0080] An example has been described in which the metal portion 106 is integrated into the resin portion 104 by insert molding. The means for integrating the metal portion 106 and the resin portion 104 is not particularly limited. The metal portion 106 and the resin portion 104 may be integrated, for example, by fitting, bonding, snap fitting, or the like. The same applies to between the rotor 38 and the resin portion 104. The same applies to between the components 108 of the detector 26 and the resin portion 104. Some of the metal portion 106, the rotor 38, and the components 108 may be integrated into the resin portion 104 by insert molding, and the rest may be integrated into the resin portion 104 by a means other than insert molding.

[0081] The above-mentioned embodiments and modified forms are merely examples. The technical ideas abstracted from these should not be interpreted as being limited to the contents of the embodiments and modified forms. Many design changes are possible in the contents of the embodiments and modified forms, such as changing, adding, and deleting components. In the above-mentioned embodiments, the contents in which such design changes are possible are emphasized by adding the notation "embodiment". However, design changes are also permitted even in contents without such notation. The hatching on the cross sections of the drawings does not limit the material of the hatched object. [Explanation of symbols]

[0082] 10...gear motor, 16...motor, 18...rotor shaft, 20...reduction gear, 22...shaft body, 26...detector, 28...brake, 30, 32, 34...bearing, 38...rotor, 42...input shaft, 78...rolling body, 84...detector arrangement portion, 86...rotor arrangement portion, 88...brake arrangement portion, 88a...convex portion, 90, 92, 94...bearing arrangement portion, 91...rolling surface, 100...shaft main body portion, 102...input shaft component portion, 104...resin portion, 106...metal portion, 110...outer cylindrical portion, 112...inner cylindrical portion, 114...metal convex portion, 118...resin concave portion.

Claims

1. A gear motor including a motor and a reducer, a rotor shaft rotated by the motor and an input shaft of the reducer are integrated into a shaft body, The shaft body has a configuration in which a resin portion made of a resin-based material and a metal portion made of a metal-based material are integrated together, the resin portion constitutes a shaft main body extending from inside the motor to inside the reduction gear, the metal portion is disposed on an outer circumferential portion of the shaft main body in the reducer, the resin portion constitutes a rotor mounting portion in which a rotor of the motor is mounted at an outer periphery thereof, The rotor is integrated with the resin portion by insert molding.

2. The gear motor according to claim 1 , wherein the metal portion constitutes a bearing mounting portion in which a bearing used in the reducer is mounted.

3. The gear motor according to claim 2 , wherein the metal portion constitutes a rolling surface along which the rolling elements of the bearing roll.

4. The gear motor according to claim 2 , wherein the metal portion constitutes the bearing mounting portion in which an inner ring of the bearing is mounted.

5. The gear motor according to claim 1 , wherein the resin portion constitutes a brake mounting portion in which a brake is mounted.

6. The gear motor according to claim 5 , wherein the brake arrangement portion comprises a plurality of protrusions spaced apart in the circumferential direction.

7. the resin portion constitutes a detector arrangement portion in which components of a detector are arranged, 7. The gear motor according to claim 1, wherein the component is integrated with the resin portion by insert molding.

8. The metal portion includes an outer tubular portion, the resin portion includes an inner tubular portion disposed inside the outer tubular portion, The outer cylindrical portion includes a metal protrusion protruding radially inward, The gear motor according to claim 7 , wherein the inner cylindrical portion is provided with a resin recess into which the metal protrusion fits.

9. 9. The gear motor according to claim 1, wherein the metal portion is integrated with the resin portion by insert molding.

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