阅读说明：本技术 马达的制造方法、马达以及电动助力转向装置 (Method for manufacturing motor, and electric power steering device ) 是由 服部隆志 冈本俊哉 西川裕一 于 2019-08-06 设计创作，主要内容包括：本发明提供马达的制造方法、马达以及电动助力转向装置，能够容易地调整向其他部件安装的安装位置。在马达(1)的制造方法中，从径向的尺寸不同的多个马达安装部件中选择一个马达安装部件(10)。壳体(20)具有第一端面(23a)。马达安装部件(10)的主体部(12)具有与第一端面(23a)对置的第二端面(12a)。在设置于第一端面(23a)和第二端面(12a)的两个以上的接合位置(25)，将壳体(20)的轴向一端与所选择的马达安装部件(10)的主体部(12)在轴向上进行接合。该制造方法还将定子(40)固定在壳体(20)内，将转子(30)安装在壳体(20)内。(The invention provides a method for manufacturing a motor, a motor and an electric power steering device, which can easily adjust the installation position of the motor to other components. In a method for manufacturing a motor (1), one motor mounting member (10) is selected from a plurality of motor mounting members having different radial dimensions. The housing (20) has a first end surface (23 a). The main body (12) of the motor mounting member (10) has a second end surface (12a) that faces the first end surface (23 a). One axial end of the housing (20) is axially joined to the body section (12) of the selected motor mounting member (10) at two or more joining positions (25) provided on the first end surface (23a) and the second end surface (12 a). The manufacturing method also fixes the stator (40) in the housing (20), and installs the rotor (30) in the housing (20).)

1. A method of manufacturing a motor, the motor having: a shaft extending along a central axis and having bearings at both axial ends; a rotor fixed to the shaft; a stator disposed radially outward of the rotor; a housing disposed radially outside the stator; and a motor mounting member for mounting the motor to another member, the motor mounting member having a main body portion facing one end in the axial direction of the housing and a flange portion projecting radially outward from the main body portion,

the manufacturing method of the motor comprises the following steps:

selecting one motor mounting member from a plurality of motor mounting members different in radial dimension;

axially engaging one axial end of the housing having a first end face with a body portion of the one motor mounting member having a second end face opposed to the first end face at two or more engagement positions provided on the first end face and the second end face;

securing the stator within the housing; and

mounting the rotor within the housing.

2. The method of manufacturing a motor according to claim 1,

the method of joining the one axial end of the housing to the main body portion of the one motor mounting member is at least one of welding and caulking.

3. The method of manufacturing a motor according to claim 2,

the staking engagement includes: in the two or more joining positions, the recess is formed by plastically deforming the one axial end of the housing and the main body portion of the one motor mounting member by pressing them in one axial direction with a jig.

4. The method of manufacturing a motor according to claim 2,

the staking engagement includes: in the two or more joining positions, a through hole that penetrates in the axial direction is formed in one of the one axial end of the housing and the main body portion of the one motor mounting member, and a portion facing the through hole is cut in a U-shape in the other of the one axial end of the housing and the main body portion of the one motor mounting member, and the U-shaped cut portion is bent so as to sandwich an outer edge of the through hole.

5. The manufacturing method of a motor according to any one of claims 1 to 4,

the plurality of joining positions are provided along a circumferential direction of the housing and are arranged on an inner diameter side of an outer periphery of the main body portion of the motor mounting member.

6. A motor, comprising:

a shaft extending along a central axis and having bearings at both axial ends;

a rotor fixed to the shaft;

a stator disposed radially outward of the rotor;

a housing that is disposed radially outside the stator and that has a first end surface and a first center hole at one axial end, the first center hole being provided at a radial center of the first end surface for the shaft to pass through;

a motor mounting member for mounting a motor to another member, the motor mounting member including a main body portion having a second end surface axially opposed to the first end surface, and a flange portion extending from an outer periphery of the main body portion to a radially outer side of the housing; and

and an engaging portion that axially engages one end of the housing with the main body of the motor mounting member and is provided on an inner diameter side of an outer periphery of the main body of the motor mounting member.

7. The motor of claim 6,

the engaging portion includes a recess that is recessed toward one axial direction and inside the housing.

8. The motor of claim 6,

the joint portion has:

a through hole provided at one axial end of the housing and at one of the main body portions of the motor mounting member, and penetrating in the axial direction; and

and a bent portion provided at one axial end of the housing and the other axial end of the body portion of the motor mounting member, and fixed by bending the axial cross-section in a U-shape so as to sandwich an outer edge of the through-hole.

9. The motor according to any one of claims 6 to 8,

a first annular wall portion extending from an inner end surface on an opposite side of the first end surface toward an inner side of the housing, surrounding the first center hole,

the first annular wall portion receives at least a portion of the bearing.

10. The motor according to any one of claims 6 to 9,

the main body of the motor mounting member includes:

a second center hole axially opposed to the first center hole, through which the shaft passes; and

and a second annular wall portion that surrounds the second center hole and extends from an outer end surface located on an opposite side of the second end surface.

11. A motor, comprising:

a shaft extending along a central axis and having bearings at both axial ends;

a rotor fixed to the shaft;

a stator disposed radially outward of the rotor;

a housing that is disposed radially outside the stator and that has a first end surface and a first center hole at one axial end, the first center hole being provided at a radial center of the first end surface for the shaft to pass through;

a motor mounting member for mounting a motor to another member, the motor mounting member including a main body portion having a second end surface axially opposed to the first end surface, and a flange portion extending from an outer periphery of the main body portion to a radially outer side of the housing; and

and an engaging portion that axially engages one end of the housing with the main body of the motor mounting member, is provided on an inner diameter side of an outer periphery of the main body of the motor mounting member, and includes a recess that is recessed axially and inwardly of the housing.

12. A motor, comprising:

a shaft extending along a central axis and having bearings at both axial ends;

a rotor fixed to the shaft;

a stator disposed radially outward of the rotor;

a housing that is disposed radially outside the stator and that has a first end surface and a first center hole at one axial end, the first center hole being provided at a radial center of the first end surface for the shaft to pass through;

a motor mounting member for mounting a motor to another member, the motor mounting member including a main body portion having a second end surface axially opposed to the first end surface, and a flange portion extending from an outer periphery of the main body portion to a radially outer side of the housing; and

an engaging portion that axially engages one end of the housing with the main body of the motor mounting member and is provided on an inner diameter side of an outer periphery of the main body of the motor mounting member,

the joint portion has:

a through hole provided at one axial end of the housing and at one of the main body portions of the motor mounting member, and penetrating in the axial direction; and

and a bent portion provided at one axial end of the housing and the other axial end of the body portion of the motor mounting member, and fixed by bending the axial cross-section in a U-shape so as to sandwich an outer edge of the through-hole.

13. An electric power steering apparatus, wherein,

the electric power steering apparatus has the motor according to any one of claims 6 to 12.

Technical Field

The invention relates to a method of manufacturing a motor, and an electric power steering apparatus.

Background

As a structure for mounting a motor to another member, a motor mounting member having a flange portion is known. The motor mounting member is fixed to one end side in the axial direction of the motor. As a method of fixing the motor mounting member to the motor, the following methods are known: a recess is formed in an outer peripheral portion of one end of the motor in the axial direction, and the recess is caulked and fixed to a projection formed in an outer peripheral portion of the motor mounting member (see, for example, patent document 1). Further, a method of caulking and fixing an outer peripheral portion of one end in the axial direction of the housing and a tapered portion of an outer peripheral portion of the motor mounting member is known (see patent document 2).

Patent document 1: japanese patent laid-open publication No. 2015-6089

Patent document 2: japanese Kokai publication Sho-64-006757

In the motors of patent documents 1 and 2, since the size of the motor mounting member corresponds to the inner diameter of the housing, the mounting position of the motor to other members is also determined by the inner diameter of the housing. Therefore, it is difficult to adjust the installation position of the motor, which is inconvenient.

Disclosure of Invention

An object of the present invention is to provide a motor manufacturing method and a motor, in which the mounting position to another member can be easily adjusted.

A method of manufacturing a motor according to an exemplary embodiment of the present application manufactures a motor including: a shaft extending along a central axis and having bearings at both axial ends; a rotor fixed to the shaft; a stator disposed radially outside the rotor; a housing disposed radially outside the stator; and a motor mounting member. The motor mounting member is used for mounting the motor to another member, and has a main body portion facing one end in the axial direction of the housing and a flange portion projecting radially outward from the main body portion. The method for manufacturing the motor comprises the following steps: selecting one motor mounting member from a plurality of motor mounting members different in radial dimension; and axially joining one axial end of the housing having the first end face and the body portion of the one motor mounting member having the second end face opposed to the first end face at two or more joining positions provided on the first end face and the second end face. The manufacturing method further includes the steps of: fixing the stator in the housing; and mounting the rotor within the housing.

According to the method of manufacturing a motor of one exemplary embodiment of the present application, one motor mounting member is selected from a plurality of motor mounting members having different radial dimensions, and the motor mounting member is fixed to the housing by joining the body portion of the motor mounting member having the first end face and the second end face opposite to the first end face at two or more joining positions provided on the first end face and the second end face. Therefore, the optimum motor mounting member can be selected from the motor mounting members having different radial dimensions without depending on the housing, and the motor can be mounted on the other member. Therefore, a motor manufacturing method and a motor in which the mounting position to another member can be easily adjusted can be realized.

Drawings

Fig. 1 is a sectional view showing a motor of a first embodiment.

Fig. 2 is a perspective view of the housing of the first embodiment as viewed from the bottom side.

Fig. 3 is a bottom view of the housing to which the motor mounting component of the first embodiment is mounted.

Fig. 4 is a sectional view of the joint portion of the first embodiment.

Fig. 5 (a), (b), and (c) are diagrams illustrating the bonding process of the first embodiment.

Fig. 6 is a sectional view of the housing to which the motor mounting component of the second embodiment is joined.

Fig. 7 is a bottom view of the housing to which the motor mounting component of the second embodiment is mounted.

Fig. 8 is a sectional view of the joint portion of the second embodiment.

Fig. 9 is a schematic view of an electric power steering apparatus according to another embodiment.

Description of the reference symbols

1: a motor; 2: an electric power steering apparatus; 10. 210: a motor mounting member; 11: a flange portion; 12: a main body portion; 12 a: a second end face; 12 b: an outer end face; 15. 215: a joint portion; 15 a: a recess; 17: mounting holes; 18: a second central aperture; 19: a second annular wall portion; 20: a housing; 23: a bottom; 23 a: a first end face; 23 b: an inner side end surface; 25: an engaged position; 27: a lower bearing retainer; 27 a: a first central aperture; 27 b: a first annular wall portion; 28: a bearing retainer; 30: a rotor; 31: a shaft; 40: a stator; 41: a stator core; 42: an insulating member; 43: a coil wire; 50: a bus bar support; 61: a bus bar; 71: an upper side bearing; 72: a lower bearing; 80: a control substrate; 90: other components; 100: a jig; 101: a punch; 101 a: a front end portion; 102: punching a die; 102 a: an aperture; 210: a motor mounting member; 215 a: a bending section; 215 c: a through hole; 215 e: an outer edge; 911: a steering member; 912: a wheel; 913: an axle; 914: a steering shaft; c: a central axis.

Detailed Description

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The scope of the present invention is not limited to the following embodiments, and may be arbitrarily changed within the scope of the technical idea of the present invention.

In the following description, the central axis of the motor is denoted by C. The direction in which the central axis C extends is assumed to be the axial direction. One of the two sides in the axial direction is an upper side, and the other side is a lower side. However, the vertical direction in the present specification is used for specifying the positional relationship, and is not limited to the actual direction and positional relationship. The direction of gravity is not necessarily the downward direction. In the present specification, a direction perpendicular to the rotation axis of the motor is referred to as a "radial direction". A direction along an arc centered on the rotation axis of the motor is referred to as "circumferential direction".

The drawings used in the following description are sometimes intended to emphasize characteristic portions, and the characteristic portions are shown enlarged for convenience. Therefore, the dimensions and proportions of the respective constituent elements are not necessarily the same as actual ones.

(first embodiment)

< Motor >

As shown in fig. 1, the motor 1 has a shaft 31, a rotor 30, a stator 40, a bus bar support 50, a housing 20, and a motor mounting member 10.

The shaft 31 extends along the center axis C, and is supported by an upper bearing 71 and a lower bearing 72 so as to be rotatable about the center axis C. The rotor 30 is fixed to a shaft 31 and rotates around a central axis C together with the shaft 31. The upper bearing 71 is held by a bearing holder 28 located above the stator 40.

The stator 40 is disposed radially outward of the rotor 30 so as to face the rotor 30. The stator 40 includes a stator core 41, an insulator 42, and a coil wire 43. The insulator 42 is attached to teeth (not shown) of the stator core 41. The coil wire 43 is an example of a conductive portion, and is formed of a conductive wire, and is wound around the teeth via the insulator 42. The lead wires drawn out from the coil wires 43 wound around the stator 40 to the upper side of the stator 40 are connected to the bus bars 61.

The bus bar 61 is held by a bus bar holder 50 made of an insulating material such as resin, and is arranged axially above the stator 40. The bus bar 61 is electrically connected to the control board 80 via an unillustrated electric wire. The control board 80 is disposed above the stator 40, and includes a drive circuit (not shown) including electronic components of the motor 1. The bus bar 61 may have an external connection terminal (not shown) connected to an external power supply.

The housing 20 is disposed radially outward of the stator 40, and the stator 40 is fixed to the inner circumferential surface of the housing 20 by shrink fitting, caulking, press fitting, bonding, or the like. The case 20 is made of a metal material, has a bottomed cylindrical shape centered on the central axis C, and has a bottom portion 23 at a lower end in the axial direction. In addition, the shape of the case 20 is not limited to a cylindrical shape. The radial cross section of the casing 20 may be polygonal, for example.

As shown in fig. 2, the housing 20 has a first end surface 23a, a first center hole 27a, and a first annular wall portion 27b at the bottom portion 23. A first center hole 27a is formed in the center of the first end surface 23a in the radial direction for passing a shaft 31 shown in fig. 1. The first annular wall portion 27b surrounds the first center hole 27a and forms a lower bearing holder 27. As shown in fig. 1, the first annular wall portion 27b extends from the inner end surface 23b located on the opposite side of the first end surface 23a toward the inside of the housing 20. The first annular wall portion 27b houses the lower bearing 72. By providing the lower bearing holder 27 inside the housing 20 in this way, the axial dimension of the motor 1 can be reduced. The height of the first annular wall 27b in the axial direction may be not a height at which the lower bearing 72 is entirely housed, but may be a height at which a part of the lower bearing 72 is housed.

As shown in fig. 1, the motor mounting member 10 is a member made of a metal material for mounting the motor to another member 90. The motor mounting member 10 is fixed to the other member 90 by bolts (not shown) or the like inserted into mounting holes 17 provided on both sides in the radial direction of the flange portion 11.

As shown in fig. 3, the motor mounting member 10 has a main body portion 12 and a flange portion 11. As shown in fig. 1, the body portion 12 has a second end surface 12a that faces the first end surface 23a of the housing 20 in the axial direction. The flange portion 11 extends from the outer periphery of the main body portion 12 to the radially outer side of the housing 20.

As shown in fig. 1, the main body portion 12 of the motor mounting member further has a second center hole 18 and a second annular wall portion 19. The second center hole 18 is axially opposed to the first center hole 27a of the housing 20, and the shaft 31 passes through it. The second annular wall portion 19 surrounds the second center hole 18 and extends in the axial direction from the outer end surface 12b located on the opposite side of the second end surface 12 a.

The bottom portion 23 of the housing 20 and the main body portion 12 of the motor mounting member 10 are joined in the axial direction via the joint portion 15. As shown in fig. 2 and 3, the engagement portions 15 are formed at four engagement positions 25, and the four engagement positions 25 are provided on the inner diameter side of the outer periphery of the main body portion 12 of the motor mounting member 10. The engagement positions 25 are arranged at equal intervals in the circumferential direction centering on the center axis C.

Each joint portion 15 is formed by caulking, for example, TOX (registered trademark) described later. As shown in fig. 4, each of the engaging portions 15 includes a recess 15a recessed inward of the housing 20 in one axial direction. The axial cross section of the engaging portion 15 or the recess 15a may be trapezoidal or rectangular as shown in the example, depending on the shape of a jig to be described later.

As described above, in the motor 1 of the above embodiment, the joint portion 15 that joins the housing 20 and the motor mounting member 10 can be formed so as not to protrude outward of the housing 20. In a conventional motor (for example, patent document 1), since the caulking portion protrudes in the radial direction outside and the axial direction of the housing, the caulking portion may come into contact with a part of another member when the motor is mounted on the other member. There is a possibility that other parts are damaged by such contact. In another conventional motor (for example, patent document 2), since a step is provided on the outer peripheral edge of one end in the axial direction of the housing, the calking portion does not protrude, but the overall length of the motor is increased. On the other hand, in the motor 1 of the above embodiment, since the portion protruding to the outside of the housing 20 is not formed, the other members 90 are not easily damaged when the motor 1 is mounted. Further, the influence of the motor mounting member 10 on the dimension of the motor 1 in the axial direction can be minimized.

< method for manufacturing motor >

In manufacturing the motor 1, first, a plurality of motor mounting members having different radial dimensions are prepared, and one of the motor mounting members is selected. The axial lower end of the housing 20 and the body portion 12 of the selected motor mounting member 10 are axially joined at four predetermined joining positions 25. The joining is performed by, for example, the following TOX (registered trademark) caulking.

As shown in fig. 5, in forming the joint 15, a jig 100 including a punch 101 and a die 102 is used. The stack of the case 20 and the body portion 12 of the motor mounting member 10 at the joining position 25 is disposed on the die 102. The punch 101 has a tip portion 101a, and the tip portion 101a has an outer surface shape corresponding to an inner surface shape of the recess portion 15a of the joint portion 15. First, as shown in fig. 5 (a), the tip end 101a of the punch 101 is disposed toward the joining position 25. Next, as shown in fig. 5 (b), the tip end portion 101a is pressed into the laminate and pressed. At this time, the body portion 12 of the motor mounting member 10 and the housing 20 are plastically deformed, and the tip end portion 101a of the punch 101 bites into the hole 102a of the die 102. As a result, the layer of the case 20 and the layer of the main body portion 12 of the motor mounting member 10 deform in accordance with the shape of the hole 102a of the die 102. As a result, as shown in fig. 5 (c), the joint portion 15 having the recess 15a recessed inward of the housing 20 in the axial direction is formed.

After the joint 15 is formed, the stator 40 is fixed in the case 20 by shrink fitting, caulking, press fitting, bonding, or the like. The rotor 30 is disposed radially inward of the stator 40.

In the above method of manufacturing the motor 1, one motor mounting member is selected from a plurality of motor mounting members having different radial dimensions, and the motor mounting member 10 is fixed to the housing 20. That is, the motor mounting member 10 can be selected according to the motor mounting position of the other member 90. Therefore, the motor 1 can be attached to the other member 90 without depending on the radial dimension Φ of the housing 20 shown in fig. 1. Therefore, a motor manufacturing method and a motor in which the mounting position to another member 90 can be easily adjusted can be realized.

(second embodiment)

A motor according to a second embodiment will be described with reference to fig. 6 to 8. The motor of the present embodiment is the same as the motor 1 of the first embodiment except for the housing 20 and the motor mounting member 10, and therefore, a part of the illustration and the description are omitted. The same components as those of the motor 1 of the first embodiment are denoted by the same reference numerals and described, and detailed description thereof is omitted.

As shown in fig. 6 and 7, the bottom portion 23 of the housing 20 of the present embodiment is axially joined to the main body portion 12 of the motor mounting member 210 via a joint portion 215. The engaging portions 215 are formed at four engaging positions 25, and the four engaging positions 25 are provided on the inner diameter side of the outer periphery of the main body portion 12 of the motor mounting member 210. As in the first embodiment, the joining positions 25 are provided at equal intervals in the circumferential direction around the center axis C.

As shown in fig. 8, each joint portion 215 has a through hole 215c and a bent portion 215 a. The through hole 215c axially penetrates the bottom 23 of the housing 20. The bent portion 215a is formed in a shape bent in a U-shape in axial cross section. Each of the bonding portions 215 is formed using a predetermined jig (not shown). First, three sides of the portion of the motor mounting member 210 corresponding to the joining position 25 are cut, and the cut portions are inserted into the through holes 215c and projected inward in the axial direction of the housing 20. Then, the protruding notch portion is bent and fixed with the outer edge 215e of the through hole 215c interposed therebetween. As a result, the housing 20 and the motor mounting part 210 are engaged.

In the motor 1 having the joint portion 215 of the present embodiment as well, since the joint portion 215 is not formed with a portion protruding to the outside of the housing 20 as in the first embodiment, the other member 90 is not easily damaged when the motor is mounted, and the influence of the motor mounting member 210 on the dimension of the motor 1 in the axial direction can be minimized. In the method of manufacturing the motor, as in the first embodiment, the motor mounting member 210 can be selected according to the motor mounting position of the other member 90, and therefore the motor can be mounted on the other member 90 without depending on the radial dimension of the housing.

The through hole 215c may be provided on the motor mounting member 210 side, and the bent portion 215a may be provided on the housing 20 side. In this case, the bent portion 215a slightly protrudes from the outer end surface 12b of the motor mounting member 210 shown in fig. 7, but the influence thereof is small.

(other embodiments)

(1)

In the first and second embodiments described above, the number and positions of the engaging portions 15, 215 are not limited to the above examples. Two or more joining portions 15 and 215 may be provided. For example, the joining portions 15 and 215 may be provided at two joining positions 25 with the center axis C therebetween. Alternatively, the joining portions 15 and 215 may be provided at five or more joining positions 25. The plurality of joining positions 25 need not be arranged at equal intervals in the circumferential direction, and may be arranged at irregular intervals. In addition, the length in the radial direction from the center axis C to each engagement position 25 also need not be constant, and may be different.

(2)

In the first and second embodiments described above, the method of forming the joint portions 15 and 215 is not limited to the above example. For example, spot welding based bonding may also be used.

(3)

The mode of the motor 1 is not limited to the first and second embodiments described above. For example, the motor 1 may be a type in which the lead line of the coil wire 43 is connected to the control board 80 without including the bus bar holder and the bus bar.

(4)

An example in which the motor 1 is mounted on the electric power steering apparatus 2 will be described with reference to fig. 9.

The electric power steering apparatus 2 is mounted on a steering mechanism of wheels 912 of an automobile. The electric power steering apparatus 2 is a column-type power steering apparatus that directly reduces a steering force by the power of the motor 1. The electric power steering apparatus 2 includes a motor 1, a steering shaft 914, and an axle 913.

The steering shaft 914 transmits an input from a steering 911 to an axle 913 having wheels 912. The power of the motor 1 is transmitted to the axle 913 through the ball screw. The motor 1 used in the column-type electric power steering apparatus 2 is disposed inside an engine room (not shown). The electric power steering apparatus 2 shown in fig. 9 is of a column type, but may be of a rack type.

The electric power steering apparatus 2 has a motor 1. Therefore, the electric power steering device 2 having the same effects as those of the above embodiment can be obtained.

Here, the electric power steering apparatus 2 is exemplified as an example of a method of using the motor 1, but the method of using the motor 1 is not limited, and can be used in a wide range of pumps, compressors, and the like.

The above-described embodiments and variations are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is defined not by the above-described embodiments but by the claims, and is intended to include all modifications equivalent in meaning and scope to the claims.