JP2007060825A - Electric motor, manufacturing method therefor and fuel pump using it - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electric motor that prevents interference between the coil winding and foreign particle, a fuel pump using it, and an electric motor manufacturing method. <P>SOLUTION: Coils 62 where windings are wound in a concentrated manner are formed on 6 pieces of slots 50 set up in the rotating direction of an armature 40. An insulating resin member 66 is filled between 6 pieces of slots 50 adjacent in the rotating direction, between the armature 40 and a commutator 70, and at the end in the direction of the rotating shaft at the side of the pump 20 opposite to the armature 40 and the commutator 70. A fuel path 204 is formed between a permanent magnet 32 of a motor 30 and the armature 40. When an impeller 26 is rotated with the armature 40 of the motor 30, a fuel sucked from an inlet 200 is pressurized at a pump flow path 202 and discharged from an outlet 206 through the fuel path 204. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an electric motor, a fuel pump using the electric motor, and a method for manufacturing the electric motor.

A motor is known in which a coil is formed by concentrating windings in a plurality of slots installed in the rotation direction of the armature, and a drive current rectified by the commutator is supplied to the coil to rotate the armature. (For example, refer to Patent Document 1).
In such an electric motor, for example, foreign objects may enter the armature from both ends in the rotation axis direction of the armature between slots adjacent in the rotation direction, and may interfere with the winding.

JP 2004-28083 A

  The present invention has been made to solve the above problems, and it is an object of the present invention to provide an electric motor that prevents interference between a winding of a coil and a foreign object, a fuel pump using the electric motor, and a method of manufacturing the electric motor.

According to the first aspect of the present invention, since the surface of the coil wound around each slot of the armature is covered with the insulating coating material, the winding that forms the coil even if foreign matter enters the armature Insulation coating material prevents interference with foreign material.
In the invention according to claims 2 to 4, since the insulating material blocks the gap between the slots adjacent in the rotation direction, foreign matter enters the armature from between the slots adjacent in the rotation direction. To prevent. Therefore, interference between the winding forming the coil and the foreign matter can be prevented.

In the inventions according to claims 5 and 6, since the insulating resin material is filled between the armature and the commutator, foreign matter enters the armature from between the armature and the commutator. To prevent. Accordingly, interference between the winding forming the coil and the foreign matter can be prevented. In the inventions according to claims 7 and 8, the end of the armature opposite to the commutator is filled with an insulating resin material. Therefore, foreign matter is prevented from entering the armature from the end of the armature opposite to the commutator in the rotation axis direction. Therefore, interference between the winding forming the coil and the foreign matter can be prevented.

By the way, when a rotating body composed of an armature and a commutator rotates, if there are gaps or irregularities on the surface of the rotating body, the resistance when the rotating body rotates increases. In particular, when the liquid is filled around the rotator, the resistance that the rotator receives from the liquid increases, and therefore the rotation of the rotator is hindered.
Accordingly, in the invention described in claims 4 to 8, at least one of the slots adjacent to each other in the rotation direction, between the armature and the commutator, or the end of the armature opposite to the commutator in the rotation axis direction. Since this is filled with the insulating resin material, the gaps and irregularities on the surface of the rotating body composed of the armature and the commutator are covered. Therefore, the resistance when the rotating body composed of the armature and the commutator rotates is reduced.
In the invention according to the tenth aspect, even when foreign matter is contained in the fuel flowing through the fuel pump, interference between the winding forming the coil wound in each slot of the armature and the foreign matter can be prevented.

Hereinafter, a plurality of embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
A fuel pump according to a first embodiment of the present invention is shown in FIG. The fuel pump 10 includes a pump unit 20, a motor unit 30 as an electric motor that rotationally drives an impeller 26 of the pump unit 20, and an end support cover 14. The housing 12 surrounds the outer periphery of the pump unit 20 and the motor unit 30 and is a common housing for the pump unit 20 and the motor unit 30. The end support cover 14 covers the opposite side of the motor unit 30 to the pump unit 20 and forms a fuel discharge port 206.

  The pump unit 20 is a Wesco pump having a pump cover 22, a pump casing 24, and an impeller 26. The pump cover 22 and the pump casing 24 are case members that accommodate the impeller 26 rotatably. A C-shaped pump flow path 202 is formed between the pump cover 22 and the impeller 26 and between the pump casing 24 and the impeller 26. The fuel sucked from the suction port 200 provided in the pump cover 22 is pressurized in the pump flow path 202 by the rotation of the impeller 26, and enters the fuel passage 204 between the permanent magnet 32 of the motor unit 30 and the armature 40. Pumped and discharged from the discharge port 206 through the fuel passage 204.

Four permanent magnets 32 formed in a quarter arc shape are attached to the inner peripheral wall of the housing 12 at equal intervals. The permanent magnet 32 forms four magnetic poles having different poles alternately in the rotation direction.
A commutator 70 is assembled to the end of the armature 40 on the opposite side of the pump unit 20 in the direction of the rotation axis. The permanent magnet 32, the armature 40, the commutator 70, and the brush (not shown) constitute a DC motor. A shaft 41 as a rotating shaft of the armature 40 is supported by a bearing member 18 that is accommodated and supported in the pump casing 24 and the bearing holder 16.

As shown in FIG. 1 and FIG. 2, the slots 50 are adjacent to each other in the rotation direction of the armature 40, between the armature 40 and the commutator 70, and opposite to the commutator 70 of the armature 40. An insulating resin material 66 is filled in the end portion in the rotation axis direction on the pump unit 20 side.
As shown in FIG. 3, the armature 40 has a central core 42 at the center of rotation. The shaft 41 is press-fitted into the central core 42. The central core 42 is formed in a cylindrical shape having a hexagonal cross section, and has a recess 44 extending in the direction of the rotation axis on each of the six outer peripheral walls. The width of the recess 44 becomes narrower toward the outer side in the radial direction.

The six slots 50 are installed on the outer periphery of the central core 42 in the rotational direction. In FIG. 3, some reference numerals of the same components are omitted. The central core 42 is formed in a hexagonal shape, and a concave portion 44 having a width narrowing toward the radially outer side is formed on each surface of the hexagon.
Each slot 50 includes a coil core 52, a bobbin 60, and a coil 62 formed by concentrating windings around the bobbin 60. As shown in FIG. 4, each slot 50 is configured by fitting a coil core 52 to a bobbin 60 around which a coil 62 is wound.

  The coil core 52 is a separate member from the central core 42. The coil core 52 is formed in a T shape. The outer peripheral surface of the coil core 52 is formed in a smooth convex arc shape. The convex portion 54 provided on the central core 42 side of the coil core 52 is wider toward the central core 42 side. By inserting the other into one of the concave portion 44 or the convex portion 54 along the shaft 41, the concave portion 44 and the convex portion 54 are fitted.

  The bobbin 60 covers the coil core 52 except for the outer peripheral surface of the coil core 52 and the convex portion 54. The bobbin 60 magnetically insulates the outer peripheral portions of the coil cores 52 adjacent in the rotation direction. In the cross section orthogonal to the shaft 41 and the cross section including the shaft 41, the bobbin 60 forms a trapezoidal winding space whose width decreases from the outer peripheral side toward the central core 42 side. A total of six coils 62 are formed by concentrating the windings in the winding space in each bobbin 60. The six coils 62 are delta-connected, and the coils 62 adjacent in the rotation direction are wound in the opposite direction. As shown in FIGS. 1 and 4, the start and end of each coil 62 are electrically connected to a terminal 64 on the commutator 70 side.

  As shown in FIG. 5, the commutator 70 includes a structure body 100 and a structure body 110. The structure 100 is formed by insert-molding 12 segments 72 installed in the rotation direction and the connection terminals 80 with a resin 74. The segments 72 are made of, for example, carbon, and the segments 72 adjacent to each other in the rotation direction are electrically insulated by a gap and an insulating resin material. The opposing segments installed on the opposite side in the radial direction are electrically connected by connection terminals 80, 82, and 84, respectively. The structure 110 is formed by insert-molding the connection terminals 82 and 84 with a resin 112. The connection by the connection terminals 80, 82, 84 is performed outside the shaft 41 in the radial direction while avoiding the shaft 41 at the center. The coil 62 is delta-connected by assembling the commutator 70 in which the structure 100 and the structure 110 are assembled to the armature 40.

  In the structure 120 shown in FIG. 6 in which the armature 40 and the commutator 70 are assembled as shown in FIGS. 4 and 5, between the slots 50 adjacent in the rotation direction and between the armature 40 and the commutator 70. The insulating resin material 66 is filled as an insulating material at the end of the armature 40 on the opposite side of the commutator 70 in the direction of the rotational axis. As a result, the gaps and irregularities in the structure 120 shown in FIG. 6 are covered with the insulating resin material 66 as shown in FIG.

The insulating resin material 66 covers the gaps and irregularities of the structure 120 as a rotating body, thereby preventing foreign matter in the fuel from entering the armature 40. As a result, interference between the windings forming the coil 62 and foreign matter can be prevented.
Further, since the insulating resin material 66 covers the gaps and irregularities of the structure 120, the resistance when the rotating body composed of the armature 40 and the commutator 70 rotates in the fuel is reduced. Further, the fuel flow through the fuel passage 204 between the permanent magnet 32 and the armature 40 is not hindered. Therefore, the motor efficiency of the motor unit 30 is improved, and the pump efficiency of the fuel pump 10 is improved.

(Second and third embodiments)
A second embodiment of the present invention is shown in FIG. 8, and a third embodiment is shown in FIG. In the second and third embodiments, the insulating resin material 66 is not filled between the slots 50 adjacent in the rotation direction. Other configurations are substantially the same as those of the fuel pump 10 of the first embodiment.

In the second embodiment shown in FIG. 8, the insulating tape 130 having elasticity is sandwiched in the gap between the slots 50 adjacent to each other in the rotation direction to block the gap between the slots 50. Insulating paper may be used instead of the insulating tape 130 as the insulating material. As described above, since the insulating tape 130 blocks the gap between the slots 50 adjacent to each other in the rotation direction, foreign matter can be prevented from entering the armature from between the slots 50 adjacent to each other in the rotation direction. Interference between the foreign matter and the winding of the coil 62 can be prevented.
In the third embodiment shown in FIG. 9, the surface of the coil 62 is covered with an insulating coating material 140. Therefore, even if a foreign object enters the armature from between the slots 50 adjacent to each other in the rotation direction, interference between the foreign object and the winding of the coil 62 can be prevented.

(Other embodiments)
In the first embodiment, all three locations between the slots 50 adjacent to each other in the rotation direction, between the armature 40 and the commutator 70, and at the end of the armature 40 on the opposite side to the commutator 70 in the rotation axis direction. Although the insulating resin material 66 is filled in, at least one of the three locations may be filled with the insulating resin material 66.
In the second and third embodiments, the insulating resin material 66 is provided only between the armature 40 and the commutator 70 or at one end of the armature 40 opposite to the commutator 70 in the rotation axis direction. Alternatively, the insulating resin material 66 may not be filled at two locations.

In the above embodiments, the impeller 26 is used as the rotating member of the pump unit 20. However, in addition to the impeller, a configuration such as a gear pump may be adopted as the rotating member of the pump unit.
In the above embodiments, the embodiment in which the present invention is applied to the fuel pump has been described. However, the present invention is not limited to this and may be applied to various electric motors.
As described above, the present invention is not limited to the above-described plurality of embodiments, and can be applied to various embodiments without departing from the gist thereof.

Sectional drawing which shows the fuel pump by 1st Embodiment. The schematic diagram which shows the slot which adjoins the rotation direction. (A) is explanatory drawing which shows the central core and coil core before an assembly | attachment, (B) is explanatory drawing which shows the central core and coil core after an assembly | attachment. Explanatory drawing which shows the slot of the armature before an assembly | attachment and after an assembly | attachment. The disassembled perspective view which shows a commutator and an armature. The perspective view which shows the armature and commutator before filling with an insulating resin material. The perspective view which shows the armature and commutator after filling with an insulating resin material. Explanatory drawing which shows the slot which adjoins the rotation direction in 2nd Embodiment. Explanatory drawing which shows the slot adjacent to a rotation direction in 3rd Embodiment.

Explanation of symbols

10: Fuel pump, 20: Pump part, 30: Motor part (electric motor), 32: Permanent magnet, 40: Armature, 50: Slot, 62: Coil, 66: Insulating resin material (insulating material), 70: Commutator , 130: insulating tape (insulating material), 140: insulating coating material

Claims (10)

Permanent magnets that are installed on the circumference and alternately form a plurality of magnetic poles with different poles;
An armature that is rotatably installed on the inner peripheral side of the permanent magnet, wherein the armature is provided with a plurality of slots having a coil formed by concentrated winding of windings in the rotation direction;
A commutator that is installed at one end of the armature in the rotation axis direction and that rectifies the current that rotates with the armature and supplies the coil;
An insulating coating covering the surface of each coil;
An electric motor. Permanent magnets that are installed on the circumference and alternately form a plurality of magnetic poles with different poles;
An armature that is rotatably installed on the inner peripheral side of the permanent magnet, wherein the armature is provided with a plurality of slots having a coil formed by concentrated winding of windings in the rotation direction;
A commutator that is installed at one end of the armature in the rotation axis direction and that rectifies the current that rotates with the armature and supplies the coil;
An insulating material that closes a gap between the slots adjacent in the rotational direction;
An electric motor.   The electric motor according to claim 2, wherein the insulating material is sandwiched between the slots adjacent in the rotation direction.   The electric motor according to claim 2, wherein the insulating material is an insulating resin material filled between the slots adjacent in the rotation direction.   The electric motor according to any one of claims 1 to 4, further comprising an insulating resin material filled between the armature and the commutator. Permanent magnets that are installed on the circumference and alternately form a plurality of magnetic poles with different poles;
An armature that is rotatably installed on the inner peripheral side of the permanent magnet, wherein the armature is provided with a plurality of slots having a coil formed by concentrated winding of windings in the rotation direction;
A commutator that is installed at one end of the armature in the rotation axis direction and that rectifies the current that rotates with the armature and supplies the coil;
An insulating resin material filled between the armature and the commutator;
An electric motor.   The electric motor according to any one of claims 1 to 6, further comprising an insulating resin material filled in an end portion of the armature on the opposite side of the commutator in the rotation axis direction. Permanent magnets that are installed on the circumference and alternately form a plurality of magnetic poles with different poles;
An armature that is rotatably installed on the inner peripheral side of the permanent magnet, wherein the armature is provided with a plurality of slots having a coil formed by concentrated winding of windings in the rotation direction;
A commutator that is installed at one end of the armature in the rotation axis direction and that rectifies the current that rotates with the armature and supplies the coil;
An insulating resin material filled in an end of the armature opposite to the commutator in the direction of the rotation axis;
An electric motor. It is a manufacturing method of the electric motor according to any one of claims 4 to 8,
A method for manufacturing an electric motor, wherein the insulating resin material is filled after the commutator is assembled to the armature. The electric motor according to any one of claims 1 to 8, wherein a fuel passage is formed between the permanent magnet and the armature.
A pump unit installed on the end side of the armature opposite to the commutator in the direction of the rotation axis and pumping fuel sucked by the rotational driving force of the armature into the fuel passage;
With fuel pump.

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