JP7767183B2 - rotating electrical machines - Google Patents

Description

The present invention relates to a rotating electric machine.

A rotating electric machine is known in which a control device that controls the current supplied to the coil wound around the motor's stator is located in the direction of the rotor's rotational axis. Rotating electric machines in which the coil and the control device are connected are also known. For example, Patent Document 1 describes an electric motor in which the ends of the windings are connected to protruding connection parts that protrude radially outward from the outer periphery of the circuit board.

Patent No. 6106841

In the electric motor described above, the protruding connection portions connected to the winding ends protrude radially outward from the outer periphery of the circuit board, which increases the size of the circuit board in the radial direction. This results in a problem of increasing the size of the electric motor in the radial direction. Furthermore, when attaching the winding ends to the circuit board, the position of the relatively flexible windings is difficult to stabilize, making the process of connecting the winding ends to the protruding connection portions cumbersome and increasing the number of steps required to manufacture the electric motor. One aspect of the present invention aims to provide a rotating electric motor that simplifies the process of connecting the coil lead wires to the control device, thereby preventing an increase in the number of steps required to manufacture the electric motor and reducing the size of the electric motor in the radial direction.

One aspect of the rotating electric machine of the present invention comprises a rotor rotatable about a central axis, a stator disposed radially outward of the rotor and facing the rotor across a radial gap, a control device located on one axial side of the stator, and a housing accommodating the rotor, the stator, and the control device. The stator includes a stator core fixed to the housing, an insulator having an insulator body surrounding at least a portion of the stator core and multiple columnar portions to which the control device is fixed, and a coil having a coil body wound around the insulator body and a coil lead wire drawn from the coil body to one axial side and connected to the control device. Each of the multiple columnar portions is columnar, extending axially from the outer edge of the insulator body to one axial side and spaced apart along the circumferential direction. The multiple columnar portions include a first columnar portion having a protrusion protruding radially inward. The protrusion is located axially between the coil body and the control device. The coil lead wire bends at the protrusion toward the control device.

One aspect of the present invention simplifies the process of connecting coil lead wires to a control device in a rotating electric machine, thereby preventing an increase in manufacturing man-hours and preventing the machine from becoming too large in the radial direction.

FIG. 1 is a schematic diagram showing a rotating electric machine according to an embodiment. FIG. 2 is a perspective view showing a part of the rotating electric machine according to the embodiment. FIG. 3 is a perspective view showing another portion of the rotating electrical machine according to the embodiment. FIG. 4 is a cross-sectional view showing a part of a rotating electric machine according to an embodiment. FIG. 5 is a perspective view showing a stator core according to one embodiment. FIG. 6 is a perspective view showing an insulator according to an embodiment. FIG. 7 is a top view showing a stator according to one embodiment. FIG. 8 is a flow chart illustrating the installation process of one embodiment. FIG. 9 is a first cross-sectional view showing the assembly procedure of the rotating electric potential of one embodiment. FIG. 10 is a second cross-sectional view showing the assembly procedure of the rotating electric potential of one embodiment. FIG. 11 is a third cross-sectional view showing the assembly procedure of the rotating electric potential of one embodiment. FIG. 12 is a fourth cross-sectional view showing the assembly procedure of the rotating electric potential of one embodiment. FIG. 13 is a fifth cross-sectional view showing the assembly procedure of the rotating electric potential of one embodiment.

The following describes a rotating electric machine according to an embodiment of the present invention, with reference to the drawings. Note that the scope of the present invention is not limited to the following embodiment, and can be modified as desired within the scope of the technical concept of the present invention. In addition, in the following drawings, the scale and number of components may differ from the actual structure in order to make each component easier to understand.

In the following description, the Z-axis is shown where appropriate in the figures. The Z-axis indicates the direction in which the central axis J of the rotating electric machine 1 of the embodiment described below extends. The central axis J shown in each figure is an imaginary axis. In the following description, the direction in which the central axis J extends, i.e., the direction parallel to the Z-axis, is referred to as the "axial direction." The radial direction centered on the central axis J is simply referred to as the "radial direction." The circumferential direction centered on the central axis J is simply referred to as the "circumferential direction." The side of the axial direction toward which the Z-axis arrow points (+Z side) is referred to as the "one axial side" or "upper side." The side of the axial direction opposite to the side toward which the Z-axis arrow points (-Z side) is referred to as the "other axial side" or "lower side." Note that the terms "upper side" and "lower side" are simply names used to describe the relative positional relationships of the various components; the actual positional relationships may be different from those indicated by these names.

The circumferential direction is indicated by the arrow θ in each diagram. The side of the circumferential direction toward which the arrow θ points (the +θ side) is called the "one circumferential side." The opposite side of the circumferential direction to the side toward which the arrow θ points (the -θ side) is called the "other circumferential side." The one circumferential side is the side that moves counterclockwise around the central axis J when viewed from above. The other circumferential side is the side that moves clockwise around the central axis J when viewed from above.

The rotating electric machine 1 of this embodiment shown in Figure 1 is a motor attached to equipment mounted on a vehicle. The equipment to which the rotating electric machine 1 is attached may be an automatic transmission or a drive unit that drives the axles of the vehicle. The rotating electric machine 1 of this embodiment is an inner rotor type three-phase brushless DC motor. The rotating electric machine 1 includes a housing 11, a rotor 20, a stator 30, and a control device 70.

The housing 11 houses the rotor 20, stator 30, and control device 70. In this embodiment, the housing 11 is made of metal. The housing 11 is electrically conductive. The housing 11 includes a housing member 12 and a cover member 13.

The housing member 12 houses the rotor 20, stator 30, and control device 70. The housing member 12 is cylindrical and extends axially around the central axis J. An opening 12d that opens upward is provided at the upper end of the housing member 12. The housing member 12 has a peripheral wall portion 12a, a bottom wall portion 12b, and a second bearing holder portion 12c.

The peripheral wall portion 12a is cylindrical and extends axially around the central axis J. The peripheral wall portion 12a surrounds the rotor 20, the stator 30, and the control device 70 from the radially outer side. The upper end of the peripheral wall portion 12a is the upper end of the housing member 12. The stator 30 is fixed to the inner circumferential surface of the peripheral wall portion 12a. An opening 12d is provided at the upper end of the peripheral wall portion 12a. An upward-facing stepped surface 12f is provided on the inner circumferential surface of the peripheral wall portion 12a.

The bottom wall portion 12b is annular and plate-shaped, with its center on the central axis J. The plate surface of the bottom wall portion 12b faces the axial direction. The radially outer end of the bottom wall portion 12b is connected to the lower end of the peripheral wall portion 12a. The bottom wall portion 12b has a hole 12e that penetrates it in the axial direction. The hole 12e is a circular hole centered on the central axis J. The second bearing retaining portion 12c protrudes upward from the bottom wall portion 12b and is annular and centered on the central axis J.

The lid member 13 is fixed to the upper end of the housing member 12. The lid member 13 covers the opening 12d from above. The lid member 13 has a lid main body portion 13a and a first bearing holder portion 13b.

The lid main body 13a is disk-shaped and centered on the central axis J. The plate surface of the lid main body 13a faces the axial direction. The outer edge of the lid main body 13a is fixed to the upper end of the housing member 12. This secures the lid member 13 to the housing member 12. The first bearing holder 13b protrudes downward from the lid main body 13a and is annular and centered on the central axis J.

The rotor 20 is rotatable around a central axis J. The rotor 20 includes a rotor core 21, a shaft 22, a plurality of magnets (not shown), a first bearing 91, and a second bearing 92.

The rotor core 21 is cylindrical and extends axially around the central axis J. The shaft 22 passes through the rotor core 21 in the axial direction. The inner circumferential surface of the rotor core 21 is fixed to the outer circumferential surface of the shaft 22. In other words, the rotor core 21 and the shaft 22 are fixed to each other. A plurality of magnets (not shown) are fixed to the rotor core 21. In this embodiment, each of the plurality of magnets is a permanent magnet. The plurality of magnets are arranged at intervals along the circumferential direction.

The shaft 22 is cylindrical and extends axially about the central axis J. The upper portion of the shaft 22 extends above the rotor core 21 and is supported by the first bearing 91. The lower portion of the shaft 22 extends below the rotor core 21 and protrudes outside the housing 11 through the hole 12e. The lower portion of the shaft 22 is supported by the second bearing 92.

As shown in FIG. 1, the first bearing 91 rotatably supports the portion of the shaft 22 above the rotor core 21. The first bearing 91 is held by the first bearing holder 13b. The second bearing 92 rotatably supports the portion of the shaft 22 below the rotor core 21. The second bearing 92 is held by the second bearing holder 12c. This allows the rotor 20 to rotate around the central axis J. In this embodiment, the first bearing 91 and the second bearing 92 are ball bearings. The first bearing 91 and the second bearing 92 may also be plain bearings.

As shown in FIG. 1, the stator 30 is disposed radially outward of the rotor 20. The stator 30 faces the rotor 20 with a radial gap between them. The stator 30 has a stator core 31, an insulator 32, and three coils 39. The stator 30 generates a magnetic field when current flows through each of the three coils 39. A rotational torque is generated in the rotor 20 by the magnetic force between the magnetic poles of the magnetic field generated in the stator 30 and multiple magnets in the rotor 20 (not shown).

As shown in FIG. 1, the stator core 31 is cylindrical and extends axially about the central axis J. The stator core 31 surrounds the rotor core 21 from the radially outer side. The outer peripheral surface of the stator core 31 is fixed to the inner peripheral surface of the peripheral wall portion 12a. In other words, the stator core 31 is fixed to the housing 11. The radially outer portion of the downward-facing surface of the stator core 31 is in axial contact with the stepped surface 12f of the housing member 12. This determines the position of the stator 30 relative to the housing 11 in the axial direction. As shown in FIG. 5, the stator core 31 has a core back portion 31a and teeth portions 31b.

The core back portion 31a is cylindrical and extends axially around the central axis J. As shown in FIG. 1, the outer peripheral surface of the core back portion 31a is fixed to the inner peripheral surface of the peripheral wall portion 12a. As shown in FIG. 5, the core back portion 31a has a first inner surface 31c. The first inner surface 31c faces radially inward of the core back portion 31a. When viewed in the axial direction, the first inner surface 31c is an arc-shaped surface. The multiple first inner surfaces 31c are arranged at equal intervals along the circumferential direction. In this embodiment, 12 first inner surfaces 31c are provided.

The teeth 31b protrude radially inward from the core back portion 31a. As shown in FIG. 1, the radially inward surface of each tooth 31b faces the outer peripheral surface of the rotor core 21 at a radially spaced interval. As shown in FIG. 5, multiple teeth 31b are arranged at equal intervals along the circumferential direction. In this embodiment, twelve teeth 31b are provided.

The insulator 32 surrounds at least a portion of the stator core 31 and insulates the stator core 31 from the coil 39. As shown in FIG. 1, the insulator 32 is disposed radially between the coil 39 and the housing 11, and insulates the coil 39 from the housing 11. In this embodiment, the insulator 32 is made of resin. The insulator 32 has insulating properties. In this embodiment, the insulator 32 is formed by injection molding. The insulator 32 has an insulator main body 33 and multiple columnar portions 34.

The insulator body 33 surrounds at least a portion of the stator core 31. As shown in FIG. 6, the insulator body 33 is the lower portion of the insulator 32. The insulator body 33 has an annular portion 33a, an inner wall portion 33b, and a housing portion 33c. The annular portion 33a has an annular shape centered on the central axis J. As shown in FIG. 1, the annular portion 33a is located above the core back portion 31a of the stator core 31. The radially outer end of the annular portion 33a is the radially outer end of the insulator body 33. In other words, the annular portion 33a is the outer edge of the insulator body 33.

As shown in FIG. 6, the inner wall portion 33b is plate-shaped and extends downward from the annular portion 33a. The plate surface of the inner wall portion 33b faces radially. When viewed in the axial direction, the inner wall portion 33b is arc-shaped. The radially inward surface of the inner wall portion 33b and the inner circumferential surface of the annular portion 33a are connected in the axial direction. Multiple inner wall portions 33b are arranged at equal intervals along the circumferential direction. In this embodiment, twelve inner wall portions 33b are provided. Each inner wall portion 33b is arranged radially inward of the first inner surface 31c of the stator core 31 shown in FIG. 5. This insulates the coil 39 from the core back portion 31a.

As shown in FIG. 6, the accommodation portion 33c has a hollow, approximately rectangular parallelepiped shape that protrudes radially inward from the inner wall portion 33b. As shown in FIG. 7, the accommodation portion 33c has a substantially rectangular shape when viewed in the axial direction. Multiple accommodation portions 33c are arranged at equal intervals along the circumferential direction. In this embodiment, twelve accommodation portions 33c are provided. Each accommodation portion 33c is arranged between adjacent inner wall portions 33b in the circumferential direction. The radially outer end of each accommodation portion 33c is connected to the inner wall portion 33b. As shown in FIG. 4, each accommodation portion 33c surrounds at least a portion of the tooth portion 31b. This insulates the coil 39 from the tooth portion 31b. Furthermore, as described above, the first inner surface 31c insulates the coil 39 from the core back portion 31a. Therefore, the insulator main body 33 insulates the coil 39 from the stator core 31.

As shown in FIG. 1, the multiple columnar portions 34 hold the control device 70. As shown in FIG. 6, each of the multiple columnar portions 34 is columnar and extends upward from the annular portion 33a, i.e., toward one axial direction. That is, each of the multiple columnar portions 34 extends upward from the outer edge of the insulator main body portion 33. As shown in FIG. 7, the multiple columnar portions 34 are arranged at equal intervals along the circumferential direction. In this embodiment, twelve columnar portions 34 are provided. As shown in FIG. 6, the radially inward surface of each columnar portion 34 is axially connected to the radially inward surface of the inner wall portion 33b. Also, as shown in FIG. 7, each columnar portion 34 is arranged circumferentially between adjacent accommodating portions 33c (i.e., slots). The multiple columnar portions 34 include a first columnar portion 35, a second columnar portion 36, and a third columnar portion 37.

As shown in FIG. 6, the first columnar portion 35 is plate-shaped and extends upward from the annular portion 33a. In this embodiment, three first columnar portions 35 are provided. As shown in FIGS. 3 and 4, the first columnar portions 35 are arranged adjacent to each other on one circumferential side of the accommodating portion 33c around which the coil main body portion 39a, from which the coil lead wire 39b (described later) is drawn out, is wound.

As shown in FIG. 6, each first columnar portion 35 has a first substrate support surface 35a and a protrusion 35b. The first substrate support surface 35a is the outer surface of the first columnar portion 35 that faces upward, i.e., toward one axial side.

The protrusion 35b has a rectangular parallelepiped shape that protrudes radially inward. As shown in FIG. 1, the protrusion 35b is located axially between the coil main body 39a (described later) and the control device 70. In the axial direction, the protrusion 35b is located below the control device 70, i.e., on the other axial side. As shown in FIGS. 6 and 7, the protrusion 35b is located above the space between adjacent accommodating portions 33c in the circumferential direction (i.e., the slots).

As shown in FIG. 7 , the radially inner end of the protrusion 35b is located radially outward of the radially inner end of the claw portion 37a, which will be described later. Therefore, according to this embodiment, interference between the protrusion 35b and a coil winding machine and winding nozzle (not shown) can be effectively prevented when winding the coil 39 around the housing portion 33c of the insulator 32. This improves the assemblyability of the stator 30, thereby preventing an increase in the number of steps required to manufacture the stator 30. This also prevents an increase in the number of steps required to manufacture the rotating electric machine 1. Furthermore, according to this embodiment, because the protrusion 35b protrudes radially inward from the first columnar portion 35, an increase in the radial size of the stator 30 can be prevented. This prevents an increase in the radial size of the rotating electric machine 1.

As shown in FIG. 6, the second columnar portion 36 is plate-shaped and extends upward from the annular portion 33a. As shown in FIG. 1, the upper end of the second columnar portion 36 is located axially lower than the upper end of the first columnar portion 35. As shown in FIG. 7, multiple second columnar portions 36 are provided at intervals along the circumferential direction. In this embodiment, five second columnar portions 36 are provided. As shown in FIG. 6, each second columnar portion 36 has a second substrate support surface 36a. The second substrate support surface 36a is the surface of the outer surface of the second columnar portion 36 that faces upward.

The third columnar portion 37 is plate-shaped and extends upward from the annular portion 33a. As shown in FIG. 1, the upper end of the third columnar portion 37 is located below the upper end of the first columnar portion 35 and above the upper end of the second columnar portion 36 in the axial direction. As shown in FIG. 7, multiple third columnar portions 37 are provided at equal intervals along the circumferential direction. In this embodiment, four third columnar portions 37 are provided. As shown in FIG. 6, each third columnar portion 37 has a claw portion 37a.

The claw portion 37a is located at the upper end of the third columnar portion 37 and protrudes radially inward. The claw portion 37a has a third board support surface 37b and a first inclined surface 37c. The third board support surface 37b is the outer surface of the claw portion 37a that faces downward, i.e., the other axial direction. As shown in FIG. 4, the third board support surface 37b is located above the second board support surface 36a. As shown in FIG. 6, the first inclined surface 37c is the outer surface of the claw portion 37a that is provided on the upper side of the claw portion 37a. The first inclined surface 37c is an inclined surface that is positioned downward as it extends radially inward.

As shown in Figures 6 and 7, the claws 37a are located above the spaces between adjacent circumferentially adjacent housing portions 33c (i.e., slots). As described above, the protrusions 35b are located above the spaces between adjacent circumferentially adjacent housing portions 33c (i.e., slots). In other words, the protrusions 35b and the claws 37a are positioned so as not to overlap the housing portions 33c when viewed axially. Therefore, a mold structure that is axially divided into two parts and has parting lines at the protrusions 35b and the claws 37a can be used for the mold for the insulator 32. This embodiment can prevent the mold structure used for injection molding the insulator 32 from becoming complicated. Furthermore, the mold shape can be simplified. This prevents increases in the number of steps and costs required to manufacture the insulator 32. This also prevents increases in the number of steps and costs required to manufacture the rotating electric machine 1.

As shown in FIG. 1, the three coils 39 are each wound around the housing portion 33c of the insulator 32. Each coil 39 is electrically connected to the control device 70. As described above, current is supplied to each of the three coils 39 from the control device 70. Each coil 39 has a coil main body portion 39a and a coil lead wire 39b.

The coil main body 39a is the portion of the coil 39 that is wound around the housing portion 33c of the insulator 32. In other words, the coil main body 39a is wound around the insulator main body 33. The coil lead wire 39b is the portion of the coil 39 that is drawn upward from the coil main body 39a, i.e., toward one axial direction. In this embodiment, each of the three coils 39 has one coil lead wire 39b. Thus, as shown in FIG. 2, three coil lead wires 39b are provided in this embodiment. As shown in FIG. 1, one end of each coil lead wire 39b is connected to the coil main body 39a. The other end of each coil lead wire 39b is connected to the control device 70. This electrically connects the control device 70 and the coil 39. The routing of the coil lead wires 39b between the coil main body 39a and the control device 70 will be described later.

The control device 70 is electrically connected to an external power source (not shown) and controls the current supplied to each of the three coils 39. The control device 70 is also electrically connected to an external device (not shown) and outputs operational information about the rotating electric machine 1, such as the rotation direction and rotation speed of the rotor 20, to the external device. As shown in FIG. 1, the control device 70 is housed inside the housing 11. The control device 70 is located above the stator 30, i.e., on one axial side. The control device 70 has a first circuit board 71, a second circuit board 72, and multiple electronic components 75.

As shown in FIG. 1, the first circuit board 71 is annular and has a plate shape centered on the central axis J. The first circuit board 71 is arranged along a plane perpendicular to the central axis J. The plate surface of the first circuit board 71 faces the axial direction. The radially outer end of the first circuit board 71 is located radially outward from the columnar portion 34. The shaft 22 passes through the first circuit board 71 in the axial direction. As shown in FIG. 4, the lower side of the first circuit board 71, i.e., the surface facing the other axial side, is in contact with the first board support surface 35a of the first columnar portion 35. This determines the axial position of the first circuit board 71.

Accordingly, according to this embodiment, there is no need to use a separate member used solely for determining the axial position of the first circuit board 71. This prevents an increase in the number of parts and manufacturing steps for the rotating electric machine 1. This also prevents an increase in the manufacturing cost of the rotating electric machine 1. Multiple electronic components 75 are attached to the first circuit board 71. As shown in FIG. 2, the first circuit board 71 has a first cutout hole 71b.

The first cutout holes 71b are holes that penetrate the first circuit board 71 in the axial direction and extend radially inward from the outer edge of the first circuit board 71. In this embodiment, three first cutout holes 71b are provided. Each first cutout hole 71b has a first connection hole portion 71c and a first guide hole portion 71d.

When viewed in the axial direction, the first connection hole 71c is circular. The other end of the coil lead wire 39b passes through the first connection hole 71c in the axial direction. The first connection hole 71c and the coil lead wire 39b are fixed with solder. In other words, the first cutout hole 71b is connected to the coil lead wire 39b. This connects the control device 70 to the coil lead wire 39b. According to this embodiment, the control device 70 and the coil lead wire 39b are directly connected without using an intermediate member such as a bus bar. This prevents an increase in the number of parts and manufacturing steps for the rotating electric machine 1. This prevents an increase in the manufacturing costs of the rotating electric machine 1.

The first guide hole 71d is a hole that connects the outer edge of the first circuit board 71 and the first connection hole 71c. The first guide hole 71d extends at an angle toward one circumferential direction from the outer edge of the first circuit board 71 toward the first connection hole 71c. In this embodiment, the first guide hole 71d extends with a uniform width from the outer edge of the first circuit board 71 toward the first connection hole 71c. The lower end of the first connection hole 71c is in contact with the first board support surface 35a of the first columnar section 35. In other words, when viewed in the axial direction, a portion of the first board support surface 35a overlaps with the first cutout hole 71b.

As shown in FIG. 1 , the second circuit board 72 has a substantially annular plate shape centered on the central axis J. The second circuit board 72 is arranged along a plane perpendicular to the central axis J. The plate surface of the second circuit board 72 faces the axial direction. The second circuit board 72 is located above the stator 30. The second circuit board 72 is also located below the first circuit board 71, i.e., on the other axial side. Therefore, according to this embodiment, the first circuit board 71 and the second circuit board 72 are arranged side by side in the axial direction, which prevents the circuit boards from becoming larger in the radial direction compared to when only one circuit board is provided. This prevents the rotating electric machine 1 from becoming larger in the radial direction.

The shaft 22 passes axially through the second circuit board 72. The radially outer end of the second circuit board 72 is located radially outward of the columnar portion 34. As shown in FIG. 3, the outer edge of the second circuit board 72 is provided with a recess 72e recessed radially inward. Although not shown, in this embodiment, seven recesses 72e are provided. One of the first columnar portion 35 or the third columnar portion 37 passes axially through each recess 72e. As shown in FIG. 4, the lower side of the second circuit board 72, i.e., the surface facing the other axial side, is in contact with the second board support surface 36a of the second columnar portion 36. Furthermore, the upper side of the second circuit board 72, i.e., the surface facing one axial side, is in contact with the third board support surface 37b of the third columnar portion 37. These elements determine the axial position of the second circuit board 72. As shown in FIG. 3, the radially outward facing surface of each recess 72e contacts the radially outward facing surface of either the first columnar portion 35 or the third columnar portion 37. This determines the radial position of the second circuit board 72. Therefore, the second circuit board 72 is held by the multiple columnar portions 34.

In other words, according to this embodiment, the second circuit board 72 can be held by the multiple columnar portions 34 of the insulator 32. Therefore, there is no need to use additional members, such as screws, to secure the second circuit board 72 to the insulator 32, the housing 11, etc. This prevents an increase in the number of parts and manufacturing steps for the rotating electric machine 1. This also prevents an increase in the manufacturing costs of the rotating electric machine 1.

As shown in FIG. 3, multiple electronic components 75 are attached to the second circuit board 72. The second circuit board 72 has second cutout holes 72b. When viewed in the axial direction, the configuration of the second cutout holes 72b is the same as the configuration of the first cutout holes 71b. Therefore, in the following description, description of configurations similar to the first cutout holes 71b may be omitted. The configuration of the second cutout holes 72b may be different from the configuration of the first cutout holes 71b. The second cutout holes 72b are holes that penetrate the second circuit board 72 in the axial direction and extend radially inward from the outer edge of the second circuit board 72. The second cutout holes 72b are positioned radially inward of the first columnar portion 35. When viewed radially, the second cutout holes 72b overlap the first columnar portion 35. In this embodiment, three second cutout holes 72b are provided. Each second cutout hole 72b has a second connection hole portion 72c and a second guide hole portion 72d.

The coil lead wire 39b passes axially through the second connection hole 72c. In other words, the second circuit board 72 has a second cutout hole 72b through which the coil lead wire 39b passes. The second guide hole 72d is a hole that connects the outer edge of the second circuit board 72 to the second connection hole 72c. The second guide hole 72d extends at an angle toward one circumferential side as it moves from the outer edge of the second circuit board 72 toward the second connection hole 72c.

As described above, the plurality of electronic components 75 are attached to the first circuit board 71 and the second circuit board 72. The plurality of electronic components 75 are fixed to the first circuit board 71 and the second circuit board 72 by soldering or the like, and are electrically connected to the first circuit board 71 and the second circuit board 72. In this embodiment, the plurality of electronic components 75 are electronic components such as capacitors, transistors, and connectors. The plurality of electronic components 75 include electronic components 75a fixed to both the first circuit board 71 and the second circuit board 72. Therefore, the first circuit board 71 and the second circuit board 72 are fixed to each other via the electronic components 75a. In this embodiment, the electronic components 75a are inter-board connectors that electrically connect the first circuit board 71 and the second circuit board 72. In this embodiment, three electronic components 75a are provided. The electronic components 75a may be partially embedded in resin by insert molding using the electronic components 75a as insert members. In this case, the strength of the resin-containing electronic component 75a can be increased, and the first circuit board 71 and the second circuit board 72 can be firmly fixed together.

In this embodiment, the first circuit board 71 and the second circuit board 72 are fixed together via the electronic components 75. Furthermore, as described above, the second circuit board 72 is held by the multiple columnar portions 34. That is, the first circuit board 71 can be held by the multiple columnar portions 34 via the second circuit board 72 and the electronic components 75a. Therefore, there is no need to use additional components, such as screws, to fix the first circuit board 71 to the insulator 32, housing 11, etc. This prevents an increase in the number of components and manufacturing steps for the rotating electric machine 1. This prevents an increase in the manufacturing costs of the rotating electric machine 1.

Next, the routing of the coil lead wires 39b will be described. Figure 4 shows the routing of two of the three coil lead wires 39b. The routing of the remaining coil lead wire 39b is similar to the routing of these two coil lead wires 39b, so its description will be omitted.

As described above, the columnar portions 34 arranged adjacent to each other on one circumferential side of the accommodating portion 33c around which the coil main body 39a, from which the coil lead wire 39b is drawn, is the first columnar portion 35. In the axial direction, the portion of the coil lead wire 39b located between the coil main body 39a and the protrusion 35b extends upward and toward one circumferential side (+θ side) to contact the downward-facing surface of the protrusion 35b and extend toward one circumferential side along the downward-facing surface of the protrusion 35b. The coil lead wire 39b located on one circumferential side of the protrusion 35b extends substantially upward along the surface of the protrusion 35b facing toward one circumferential side. In other words, the coil lead wire 39b is bent at the protrusion 35b toward the control device 70.

As described below, in the manufacturing process of the rotating electric machine 1, in the first step S01 of the attachment process Pf, the coil lead wire 39b is hooked onto the protrusion 35b and pulled upward by a worker or the like, so that the coil lead wire 39b is wound around the protrusion 35b. This reduces variation in the circumferential and radial position of the coil lead wire 39b above the protrusion 35b. Furthermore, in the axial direction, the portion of the coil lead wire 39b between the coil main body 39a and the protrusion 35b is positioned radially inward of the first columnar portion 35.

The coil lead wire 39b above the protrusion 35b extends generally upward and passes axially through the second cutout hole 72b of the second circuit board 72 and the first cutout hole 71b of the first circuit board 71. More specifically, the coil lead wire 39b passes axially through the second connection hole 72c and the first connection hole 71c. Therefore, the coil lead wire 39b above the protrusion 35b is positioned radially inward of the first columnar portion 35. As described above, the coil lead wire 39b between the coil main body 39a and the protrusion 35b in the axial direction is positioned radially inward of the first columnar portion 35. In other words, the coil lead wire 39b overlaps the first columnar portion 35 when viewed radially. The other end of the coil lead wire 39b is fixed to the first connection hole 71c by soldering. This electrically connects the first circuit board 71 and the coil 39. In other words, the control device 70 and the coil 39 are electrically connected.

Next, we will explain the attachment process Pf, which is one of the manufacturing processes for the rotating electric machine 1 of this embodiment, in which the control device 70 is attached to the stator 30 and the stator 30 with the attached control device 70 is attached to the housing 11. As shown in Figure 8, the attachment process Pf of this embodiment includes a first step S01 of hooking the coil lead wire 39b onto the protrusion 35b and bending it upward; a second step S02 of passing the coil lead wire 39b through the second cutout hole 72b of the second circuit board 72; a third step S03 of passing the coil lead wire 39b through the first cutout hole 71b of the first circuit board 71; a fourth step S04 of holding the control device 70 on the insulator 32; a fifth step S05 of connecting the other end of the coil lead wire 39b to the first circuit board 71; and a sixth step S06 of attaching the stator 30 with the attached control device 70 to the housing 11. In the following description, "workers, etc." includes the workers who perform each task and the assembly equipment, etc. Each task may be performed by the worker alone, by the assembly equipment alone, or by both the worker and the assembly equipment.

In the first step S01, the worker or the like hooks the coil lead wire 39b onto the protrusion 35b and bends it upward. As shown in FIG. 9 , the worker or the like pulls the coil lead wire 39b (indicated by the two-dot chain line) drawn upward from the coil main body 39a toward one circumferential side (+θ side) and passes it under the protrusion 35b toward one circumferential side (+θ side). The worker or the like then hooks the coil lead wire 39b onto the downward-facing surface of the protrusion 35b and pulls it upward. At this time, one portion of the coil lead wire 39b contacts the downward-facing surface of the protrusion 35b, and the other portion of the coil lead wire 39b contacts the surface of the protrusion 35b facing one circumferential side (+θ side). As a result, the portion of the coil lead wire 39b above the protrusion 35b extends upward, i.e., toward the control device 70. Furthermore, as described above, the coil lead wire 39b wraps around the protrusion 35b and extends upward, stabilizing the circumferential and radial positions of the portion of the coil lead wire 39b above the protrusion 35b.

In the second step S02, the worker passes the coil lead wire 39b through the second cutout hole 72b in the second circuit board 72. After completing the first step S01, the worker moves the control device 70 from the top to the bottom of the stator 30, as shown in FIG. 9. At this time, multiple electronic components 75 have already been attached to the first circuit board 71 and the second circuit board 72 of the control device 70, and the first circuit board 71 and the second circuit board 72 are fixed to each other via the electronic component 75a.

As shown in FIG. 10 , the worker moves the control device 70 until the second circuit board 72 is positioned above the upper end of the first columnar portion 35 and below the other end of the coil lead wire 39b. Then, the worker grasps the portion of the coil lead wire 39b above the first columnar portion 35 and passes the coil lead wire 39b through the second cutout hole 72b from the radially outer side of the second circuit board 72. More specifically, the worker inserts the coil lead wire 39b into the second guide hole 72d from the radially outer end of the second guide hole 72d shown in FIG. 3 and moves the coil lead wire 39b along the second guide hole 72d to the second connection hole 72c. This causes the coil lead wire 39b to pass axially through the second connection hole 72c. In other words, the coil lead wire 39b is passed axially through the second cutout hole 72b.

According to this embodiment, as described above, the second circuit board 72 has second cutout holes 72b extending radially inward from the outer edge of the second circuit board 72. This allows the coil lead wire 39b to be inserted into the second cutout holes 72b from the radially outer side of the second circuit board 72. If the second cutout holes 72b were not connected to the outer edge of the second circuit board 72, the coil lead wire 39b would need to be passed through the second cutout holes from below. In this case, it would be difficult for workers to confirm the relative positions of the coil lead wire 39b and the second cutout holes 72b in the radial and circumferential directions, making it difficult to pass the coil lead wire 39b through the second cutout holes. In contrast, in this embodiment, workers can confirm the radially outer position of the second cutout holes 72b, making it easy to insert the coil lead wire 39b into the second cutout holes 72b. This simplifies the work of the second step S02, thereby simplifying the work of connecting the coil lead wire 39b to the control device 70. This prevents an increase in the number of steps required to manufacture the rotating electric machine 1.

Furthermore, according to this embodiment, the second guide hole portion 72d extends at an angle toward one circumferential side (the +θ side) as it extends radially inward from the outer edge of the second circuit board 72, thereby preventing the coil lead wire 39b from slipping out radially outward from the second cutout hole 72b. This prevents an increase in the number of manufacturing steps for the rotating electric machine 1.

Furthermore, in this embodiment, the coil lead wire 39b extends upward, bypassing one circumferential side (+θ side) of the protrusion 35b, and because the coil lead wire 39b has a certain degree of rigidity, the coil lead wire 39b above the protrusion 35b tends to move toward one circumferential side. As described above, the second guide hole portion extends at an angle toward one circumferential side (+θ side) as it extends radially inward from the outer edge of the second circuit board 72. Therefore, when the coil lead wire 39b moves toward one circumferential side within the second cutout hole 72b, the coil lead wire 39b moves along the second guide hole portion toward the second connection hole 72c. This effectively prevents the coil lead wire 39b from slipping out radially outward from the second cutout hole 72b. This simplifies the process of connecting the coil lead wire 39b to the control device 70. This effectively prevents the number of manufacturing steps for the rotating electrical machine 1 from increasing.

Furthermore, as described above, according to this embodiment, in the first step S01, the coil lead wire 39b is hooked onto the protrusion 35b and pulled upward, which makes it easier to stabilize the radial and circumferential position of the coil lead wire 39b located above the protrusion 35b. This allows workers to easily grasp the coil lead wire 39b and easily pass the coil lead wire 39b through the second cutout hole 72b. This simplifies the process of connecting the coil lead wire 39b to the control device 70. This more effectively prevents an increase in the number of steps required to manufacture the rotating electric machine 1.

In the third step S03, the worker passes the coil lead wire 39b through the first cutout hole 71b of the first circuit board 71. After completing the second step S02, the worker moves the control device 70 downward. As shown in FIG. 11 , the worker moves the control device 70 until the first circuit board 71 is positioned above the upper end of the first columnar portion 35 and below the other end of the coil lead wire 39b. Then, the worker grasps the portion of the coil lead wire 39b above the first columnar portion 35 and passes the coil lead wire 39b through the first cutout hole 71b from the radially outer side of the first circuit board 71. More specifically, the worker inserts the coil lead wire 39b into the first guide hole 71d from the radially outer end of the first guide hole 71d shown in FIG. 2 and moves the coil lead wire 39b along the first guide hole 71d to the first connection hole 71c. As a result, the coil lead wire 39b is passed axially through the first connection hole portion 71c. In other words, the coil lead wire 39b is passed axially through the first cutout hole 71b.

According to this embodiment, as described above, the first circuit board 71 has the first cutout holes 71b extending radially inward from the outer edge of the first circuit board 71. This allows the coil lead wires 39b to be inserted into the first cutout holes 71b from the radially outer side of the first circuit board 71. This allows workers to confirm the radially outer position of the first cutout holes 71b and easily insert the coil lead wires 39b into the first cutout holes 71b. This simplifies the work of the third step S03. This simplifies the work of connecting the coil lead wires 39b to the control device 70. This prevents an increase in the number of steps required to manufacture the rotating electric machine 1.

Furthermore, according to this embodiment, the first guide hole portion 71d extends at an angle toward one circumferential side (the +θ side) as it extends radially inward from the outer edge of the first circuit board 71, thereby preventing the coil lead wire 39b from slipping out radially outward from the first cutout hole 71b. This prevents an increase in the number of manufacturing steps for the rotating electric machine 1.

Furthermore, in this embodiment, because the coil lead wire 39b is passed axially through the second cutout hole 72b, the radial and circumferential position of the coil lead wire 39b located above the second circuit board 72 is stabilized. This allows workers to easily grasp the coil lead wire 39b and pass it through the first cutout hole 71b. This simplifies the process of connecting the coil lead wire 39b to the control device 70. This effectively prevents an increase in the number of steps required to manufacture the rotating electric machine 1.

In the fourth step S04, the control device 70 is fixed to the insulator 32. After the third step S03 is completed, the worker or the like moves the control device 70 downward. At this time, the downward-facing surface of the second circuit board 72 comes into contact with the first inclined surface 37c of the third columnar portion 37, so that a radially outward force is applied to the third columnar portion 37, causing the third columnar portion 37 to deform radially outward. This allows the control device 70 to be moved further downward.

When the worker or other person further moves the control device 70 downward, as shown in FIG. 12 , the downward-facing surface of the first circuit board 71 comes into contact with the first board support surface 35a of the first columnar portion 35, and the downward-facing surface of the second circuit board 72 comes into contact with the second board support surface 36a of the second columnar portion 36. At this time, the upward-facing surface of the second circuit board 72 and the third board support surface 37b of the third columnar portion 36 are in the same position in the axial direction, so the elastic force of the third columnar portion 37 moves radially inward, and the upward-facing surface of the second circuit board 72 comes into contact with the third board support surface 37b of the third columnar portion. As a result, the control device 70 is held by the insulator 32. In other words, the control device 70 is held by the stator 30.

In this embodiment, the protrusion 35b is located axially below the control device 70, i.e., on the other axial side. Therefore, in the second step S02 to the fourth step S04, when the control device 70 is held on the stator 30, interference between the control device 70 and the protrusion 35b can be prevented. This makes it easy to hold the control device 70 on the stator 30. This more effectively prevents an increase in the number of manufacturing steps for the rotating electric machine 1.

Furthermore, according to this embodiment, when viewed in the axial direction, a portion of the first board support surface 35a overlaps with the first cutout hole 71b. Furthermore, the first board support surface 35a overlaps with the downward-facing surface of the first circuit board 71. Therefore, the first columnar portion 35 can effectively prevent the coil lead wire 39b from moving radially outward. Therefore, the coil lead wire 39b can effectively be prevented from slipping out radially outward through the first cutout hole 71b. Therefore, an increase in the number of steps required to manufacture the rotating electric machine 1 can be more effectively prevented.

In the fifth step S05, the worker connects the other end of the coil lead wire 39b to the first circuit board 71. After completing the fourth step S04, the worker checks the position of the coil lead wire 39b inside the first cutout hole 71b. If the coil lead wire 39b is positioned in the first guide hole 71d, the worker moves the coil lead wire 39b radially inward and passes it through the first connection hole 71c. The worker then cuts the portion of the coil lead wire 39b above the first circuit board 71 to adjust the length of the coil lead wire 39b protruding upward from the first circuit board 71. Note that the length of the coil lead wire 39b protruding upward from the first circuit board 71 does not necessarily need to be adjusted. The worker then fixes the other end of the coil lead wire 39b to the first connection hole 71c by soldering. This electrically connects the coil 39 and the control device 70.

In sixth step S06, the worker or the like attaches the stator 30 that holds the control device 70 to the housing 11. After fifth step S05 is completed, as shown in FIG. 12, the stator 30 that holds the control device 70 is inserted into the housing member 12 through the opening 12d of the housing member 12, which is held by a jig or the like. As shown in FIG. 1, when the stator 30 is inserted until the outer edge of the downward-facing surface of the stator core 31 contacts the stepped surface 12f of the housing member 12, the axial position of the stator 30 relative to the housing member 12 is determined and the stator 30 is fixed to the housing member 12. In other words, the stator 30 is attached to the housing 11.

In this embodiment, the coil lead wire 39b is located radially inward of the first columnar portion 35, and overlaps the first columnar portion 35 when viewed radially. Therefore, when inserting the stator 30 holding the control device 70 into the housing 11, contact between the housing 11 and the coil lead wire 39b can be prevented. This makes it easy to insert the stator 30 holding the control device 70 into the housing 11. This effectively prevents an increase in the number of manufacturing steps for the rotating electric machine 1. Furthermore, damage to the coil lead wire 39b due to contact with the housing 11 can be prevented. This effectively ensures the insulation of the coil lead wire 39b.

According to this embodiment, the stator 30 includes a stator core 31 fixed to the housing 11, an insulator 32 having an insulator main body 33 surrounding at least a portion of the stator core 31 and a plurality of columnar portions 34 to which the control device 70 is fixed, and a coil 39 having a coil main body 39a wound around the insulator main body 33 and a coil lead wire 39b drawn from the coil main body 39a to one axial side and connected to the control device 70. Each of the plurality of columnar portions 34 is columnar, extending axially from the outer edge of the insulator main body 33 to one axial side and arranged at intervals along the circumferential direction. The plurality of columnar portions 34 includes a first columnar portion 35 having a protrusion 35b protruding radially inward. The protrusion 35b is located axially between the coil main body 39a and the control device 70, and the coil lead wire 39b is bent at the protrusion 35b toward the control device 70. This stabilizes the radial and circumferential positions of the coil lead wires 39b above the protrusions 35b. This simplifies the process of connecting the coil lead wires 39b to the control device 70 when attaching the control device 70 to the stator 30. This prevents an increase in the number of steps required to manufacture the rotating electric machine 1.

Furthermore, in this embodiment, as described above, the radial position of the coil lead wire 39b above the protrusion 35b is stable, making it easy to provide a gap between the housing 11 and the coil lead wire 39b. This makes it easy to ensure insulation between the housing 11 and the coil lead wire 39b. Therefore, it is no longer necessary to ensure insulation between the coil lead wire 39b and the housing 11 by wrapping an insulator such as Nitoflon tape around the coil lead wire 39b. This reduces the number of manufacturing steps and manufacturing costs for the rotating electric machine 1. Furthermore, because it is easy to provide a gap between the housing 11 and the coil lead wire 39b, the diameter of the housing 11 can be reduced. This prevents the rotating electric machine 1 from becoming too large in the radial direction.

Furthermore, in this embodiment, as described above, by hooking the coil lead wire 39b onto the protrusion 35b and pulling it upward, the coil lead wire 39b is forced to face upward, thereby suppressing variations in the radial and circumferential positions of the coil lead wire 39b above the protrusion 35b. This eliminates the need for additional components to regulate the radial and circumferential positions of the coil lead wire 39b. This prevents an increase in the number of parts and manufacturing costs of the rotating electric machine 1.

In this embodiment, the coil lead wire 39b overlaps the first columnar portion 35 when viewed in the radial direction, and is positioned radially inward of the first columnar portion 35. In other words, the insulating first columnar portion 35 can be positioned radially between the coil lead wire 39b and the housing 11. This more effectively ensures insulation between the housing 11 and the coil lead wire 39b.

The present invention is not limited to the above-described embodiment, and other configurations and methods may be adopted within the scope of the technical concept of the present invention. The protrusion may have any configuration as long as it can hook the coil lead wire. For example, the protrusion may be cylindrical and protrude radially inward, or may have a triangular prism shape or other shape. Furthermore, the protrusion may be a separate member from the first columnar portion that is fixed to the first columnar portion.

The multiple pillars may have any configuration as long as they are capable of holding the control device and are positioned radially between the coil lead wires and the housing. For example, the multiple pillars may be separate components from the insulator main body. Furthermore, the number of multiple pillars is not limited to 12, and may be 11 or less, or 13 or more.

The control device may have any configuration as long as it can supply current to the stator. For example, the number of circuit boards is not limited to two, and may be one, or three or more. Furthermore, the two circuit boards do not need to be fixed to each other by electronic components, but may be fixed to other members. Furthermore, the two circuit boards do not need to be fixed to each other. The control device may be fixed to other members, such as a housing.

Although the embodiments of the present invention have been described above, the applications of the rotating electric machine to which the present invention is applied are not particularly limited. The rotating electric machine is not limited to a motor, but may also be a generator. The configurations and combinations thereof in the embodiments of the present invention are merely examples, and additions, omissions, substitutions, and other modifications of the configurations are possible within the scope of the spirit of the present invention.

1... Rotating electric machine, 11... Housing, 20... Rotor, 30... Stator, 31... Stator core, 31a... Core back portion, 31b... Teeth portion, 32... Insulator, 33... Insulator main body portion, 33c... Storage portion, 34... Columnar portion, 35... First columnar portion, 35a... First board support surface, 35b... Protrusion portion, 36... Second columnar portion, 36a... Second board support surface, 37... Third columnar portion, 37a... Claw portion, 37b... Third board support surface, 39... Coil, 39a... Coil main body portion, 39b... Coil lead wire, 70... Control device, 71... First circuit board, 71b... First cutout hole, 71c... First connection hole portion, 71d... First guide hole portion, 72... Second circuit board, 72b... Second cutout hole, J... Center axis

Claims (12)

a rotor rotatable about a central axis;
a stator disposed radially outside the rotor and facing the rotor with a gap in the radial direction;
a control device located on one axial side of the stator;
a housing that accommodates the rotor, the stator, and the control device;
Equipped with
The stator includes:
a stator core fixed to the housing;
an insulator including an insulator body portion surrounding at least a portion of the stator core and a plurality of pillar portions to which the control device is fixed;
a coil including a coil body portion wound around the insulator body portion and a coil lead wire drawn out from the coil body portion to one side in the axial direction and connected to the control device;
and
each of the plurality of columnar portions has a columnar shape extending from an outer edge portion of the insulator body portion toward one side in the axial direction and arranged at intervals along the circumferential direction;
the plurality of columnar portions include a first columnar portion having a protrusion protruding radially inward,
the protrusion is located between the coil body and the control device in the axial direction,
The coil lead wire is bent at the protrusion toward the control device. When viewed in the radial direction, the coil lead wire overlaps the first columnar portion,
The rotating electric machine according to claim 1 , wherein the coil lead wire is located radially inward of the first columnar portion. The stator core includes an annular core back portion extending in the axial direction,
a plurality of teeth protruding radially inward from the core back portion and arranged at intervals along a circumferential direction;
and
the insulator body has a plurality of housing portions surrounding at least a portion of each of the teeth,
The rotating electric machine according to claim 1 , wherein the protrusions are provided on one axial side between the accommodating portions adjacent to each other in the circumferential direction. the control device has a first circuit board that is disposed along a plane perpendicular to the central axis and is connected to the coil lead wire;
4. The rotating electric machine according to claim 1, wherein the first circuit board has a first cutout hole that penetrates the first circuit board in the axial direction, extends radially inward from an outer edge of the first circuit board, and is connected to the coil lead wire. the first cutout hole has a first guide hole portion extending with a uniform width from an outer edge of the first circuit board, and a first connection hole portion connected to the first guide hole portion and to which the coil lead wire is connected,
The rotating electric machine according to claim 4 , wherein the first guide hole portion extends at an incline toward one circumferential side from an outer edge of the first circuit board toward the first connection hole portion. The rotating electric machine according to claim 4 or 5, wherein the control device has a second circuit board arranged along a plane perpendicular to the central axis and located on the other axial side of the first circuit board. The rotating electric machine according to claim 6, wherein the second circuit board has a second cutout hole that penetrates the second circuit board in the axial direction, extends inward from the outer edge of the second circuit board, and passes through the coil lead wire. the plurality of columnar portions include a second columnar portion and a third columnar portion,
the second columnar portion has a second board support surface facing one axial side, the second board support surface being in contact with a surface of the second circuit board facing the other axial side;
The third columnar portion has a claw portion that protrudes radially inward,
8. The rotating electric machine according to claim 6, wherein the claw portion has a third board support surface facing the other axial side, and the third board support surface contacts a surface of the second circuit board facing the one axial side. A rotating electric machine as described in claim 8, wherein the radially inner end of the protrusion is located radially outward of the radially inner end of the claw. A rotating electric machine according to any one of claims 4 to 9, wherein the first columnar portion has a first board support surface facing one axial side, and the first board support surface contacts a surface of the first circuit board facing the other axial side. The rotating electric machine according to claim 10, wherein a portion of the first substrate support surface overlaps with the first cutout hole when viewed in the axial direction. A rotating electric machine according to any one of claims 1 to 11, wherein the protrusion is located on the other axial side of the control device.