JP2007318987A - Motor and pump comprising magnetic sensor, method of manufacturing stator, and manufacturing method of motor and pump - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reliable brushless motor capable of precisely detecting magnetic pole of a hall element, along with a pump mounted with it, and manufacturing method thereof. <P>SOLUTION: A hall element holder 62a3 is integrally molded with an annular ring 62a2 of an insulator 62 of a stator 60. After a hall element 71 is stored in the hall element holder 62a3, a circuit board 70 is fixed to the lower case 10, so that the hall element 71 is connected to the circuit board 70. With this configuration, the position of the circuit board 70 can be adjusted in circumferential and radial direction not to apply a stress to the terminal of the hall element 71. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a motor using a magnetic sensor which is a position detecting means, and a pump for circulating a liquid. In particular, the present invention relates to a pump that is mounted on a vehicle equipped with a hybrid engine and circulates water. The present invention also relates to a method for attaching a circuit board having a magnetic sensor and a stator, a method for manufacturing a motor using this method, and a method for manufacturing a pump.

In recent years, a hybrid engine in which an electric motor and an engine are used in combination in a drive unit has been increasingly adopted as a measure for improving the fuel efficiency of a vehicle. Along with this, the mounting of electronic devices on the drive unit of vehicles is progressing. Particularly in a hybrid engine, the output of the battery is important. However, the output of the battery varies depending on the ambient temperature around the battery. Therefore, in order to keep the ambient temperature around the battery constant, the battery is cooled and heated by circulating water around the battery with a pump so as to keep the battery temperature constant.

FIG. 13 shows the structure of a conventional pump. FIG. 13: is the schematic cross section which cut the axial direction which showed the conventional pump.

Referring to FIG. 13, the pump 1 has a bottomed cylindrical partition wall 4 that separates the pump chamber 2 and the electric control unit 3, a lower case 5 that houses the electric control unit 3, and a suction port and a discharge port. An upper case 6 attached to the lower case 5 and the partition wall 4, an impeller 7 having a rotor magnet 7a disposed on the inner peripheral side of the partition wall 4, a stator 8 disposed on the outer peripheral surface of the partition wall 4, The circuit board 9 is electrically connected to the stator 8 and is arranged to face the bottom portion 4a of the partition wall 4 in the axial direction. A hall element 9a is mounted on the upper surface of the circuit board 9 so as to face the end face of the rotor magnet 7a.

JP 09-317684 A

However, since the hall element 9a in the pump 1 has no position adjusting means for the stator 8, an operator must visually determine the position of the hall element 9a with respect to the circumferential direction of the stator 8 when the pump 1 is assembled. I had to. Therefore, the position of the hall element 9a with respect to the circumferential direction of the stator 8 varies depending on the operator. As a result, there is a possibility that the characteristics of each product of the pump 1 may vary.

A bottom 4a of the partition wall 4 is disposed between the rotor magnet 7a and the hall element 9a. The distance between the rotor magnet 7a and the Hall element 9a must be increased by the amount of the partition 4 text. Therefore, it is necessary to reduce the thickness of the bottom 4a of the partition wall 4. However, the bottom 4a of the partition wall 4 is a place where a large water pressure is applied as the impeller 7 rotates. Therefore, if the thickness of the bottom portion 4a is reduced, the strength of the bottom portion 4a is lowered, and the bottom portion 4a may be deformed or cracked by water pressure. As a result, the water in the pump chamber 2 may leak from the partition wall 4, and the circuit board 9 may be short-circuited.

On the other hand, if the thickness of the bottom 4a is increased in order to prevent water leakage, the distance between the rotor magnet 7a and the hall element 8a increases, and the magnetic pole of the rotor magnet 7a is detected by the hall element 9a. The problem that accuracy to perform falls will occur. As a result, there may occur a problem that the rotation control of the impeller 7 cannot be performed with high accuracy.

Furthermore, since the Hall element 9a is connected to the circuit board 9 only by soldering, vibration due to the driving of the pump 1 may be transmitted to the circuit board 9 and the Hall element 9a may come off. Since no countermeasure is taken against the possibility of the Hall element 9a coming off, the pump is not highly reliable.

The present invention has been made in view of the above problems, and an object of the present invention is to accurately detect a magnetic pole of a Hall element and to have a highly reliable brushless motor and a pump equipped with the brushless motor. Is to provide.

According to claim 1 of the present invention, the motor has a center coaxial with the rotation center axis, and has an annular core back portion and a diameter facing the rotation center axis away from the core back portion in the circumferential direction. An insulator having a stator core composed of a plurality of teeth extending in a direction, and an annular ring that covers at least the teeth of the stator core and electrically insulates, and is connected to the inner periphery of the teeth in the circumferential direction. And a coil that is formed by winding a plurality of conductive wires through the insulator in the teeth portion, and a circuit that is disposed so as to face the insulator in the axial direction and has a magnetic sensor mounted thereon A sensor holder in which at least a part of the magnetic sensor is accommodated in the annular ring of the insulator. I am characterized in.

According to claim 1 of the present invention, the position of the magnetic sensor can be easily determined by providing the sensor holder on the annular ring of the insulator. Furthermore, the magnetic sensor can be prevented from coming into contact with other members. Therefore, a highly reliable motor can be provided.

According to claim 2 of the present invention, according to claim 1, the sensor holder has a concave shape in which an inner peripheral surface of the annular ring is recessed outward in the radial direction.

According to a third aspect of the present invention, in accordance with the second aspect, the sensor holder has a reduced width portion whose width in the circumferential direction becomes narrower toward the inside in the radial direction.

According to claim 2 and claim 3 of the present invention, the sensor holder has a shape in which the inner peripheral surface of the annular ring is recessed radially outward, and a reduced width portion is formed radially inward. Therefore, it is possible to restrict the magnetic sensor from moving inward in the radial direction. In addition, the magnetic sensor can be easily inserted into the sensor holder.

According to a fourth aspect of the present invention, according to any one of the first to third aspects, the inner surface of the sensor holder, which is the innermost circumferential surface farthest from the central axis, is And a planar shape extending in a vertical direction.

According to a fifth aspect of the present invention, in accordance with the fourth aspect, a projection extending radially outward is formed on the inner surface of the sensor holder, and the projection and the magnetic sensor are in contact with each other. And

According to the fourth and fifth aspects of the present invention, the magnetic sensor can be easily held at the desired radial position by the protrusion. Therefore, the position accuracy of the magnetic sensor can be improved.

According to claim 6 of the present invention, in accordance with claim 5, the sensor holder is formed with a bottom surface facing the end surface in the axial direction of the magnetic sensor, of the bottom surface around the protrusion, A concave portion that is recessed downward is formed.

According to claim 6 of the present invention, a curved surface can be generally formed at the connecting portion between the protrusion and the bottom surface. However, by providing a concave portion, the curved surface shape can be arranged to be equal to or below the bottom surface. Can be accurately arranged on the sensor holder.

According to claim 7 of the present invention, according to any one of claims 1 to 6, the magnetic sensor is a Hall element, and the Hall element has a plurality of legs connected to the circuit board. The leg portion is attached with a guide member having a plurality of through holes through which the leg portion passes.

According to claim 7 of the present invention, the movement of the leg portion can be restricted by attaching the guide member to the leg portion of the Hall element, so that disconnection can be prevented. Therefore, a highly reliable motor can be provided.

According to an eighth aspect of the present invention, in accordance with the seventh aspect, the guide member is attached to the circuit board, and the plurality of through holes of the guide member are inclined to increase in diameter as they are separated from the circuit board. It has a surface.

According to claim 8 of the present invention, by providing the inclined surface in the through-hole, the diameter of the through-hole on the side inserted by the inclined surface is increased to insert the leg portion of the Hall element into the through-hole. The leg portion can be easily inserted.

According to a ninth aspect of the present invention, according to any one of the seventh and eighth aspects, the peripheral wall covering at least both sides of the plurality of leg portions of the Hall element is provided above the through hole in the guide member. Is formed.

According to claim 9 of the present invention, the movement of the leg portion can be restricted by the peripheral wall, and the leg portion can be prevented from being disconnected.

According to a tenth aspect of the present invention, there is provided a rotor having a rotor magnet that rotates along a rotation center axis and an impeller that rotates integrally with the rotor magnet, and is coaxial with the rotation center axis. A stator core having an annular core back portion and a plurality of teeth portions circumferentially spaced from the core back portion and extending radially toward the rotation center axis, and at least the teeth of the stator core A stator having an insulator for covering and electrically insulating, a coil formed by winding a plurality of conductive wires through the insulator in the teeth portion, and facing the insulator in the axial direction. The circuit board to which the magnetic sensor is connected is separated from the rotating part and the stator, and the cylindrical part and the bottom part are separated from each other. An upper case having partition wall, and the lower case having, for forming a pump chamber by the lower case and the combine, the water inlet and water outlet for,
And a sensor holder that accommodates at least a part of the Hall element is formed on the insulator.

According to claim 10 of the present invention, the position of the magnetic sensor can be easily determined by providing the sensor holder on the annular ring of the insulator. Furthermore, the magnetic sensor can be prevented from coming into contact with other members. Therefore, a highly reliable pump can be provided. Further, the sensor holder can easily and accurately position the magnetic sensor, and an efficient pump can be provided.

According to an eleventh aspect of the present invention, according to the tenth aspect, the insulator includes an annular ring formed on an inner peripheral side of the teeth portion, and the sensor holder includes an inner ring of the annular ring. The sensor holder is formed on a peripheral surface and faces the cylindrical portion of the partition wall in a radial direction.

According to a twelfth aspect of the present invention, according to any one of the tenth and eleventh aspects, the sensor holder is formed in a concave shape that dents the annular ring radially outward. The peripheral opening is blocked by the outer peripheral surface of the partition wall.

According to the eleventh and twelfth aspects of the present invention, the magnetic sensor can be prevented from moving in the radial direction by closing the inner peripheral opening of the sensor holder with the partition wall. Further, since the magnetic sensor can be brought close to the partition wall, it can be brought closer to the rotor magnet. Therefore, the magnetic sensor can detect more magnetic flux of the rotor magnet. In particular, in the configuration in which the stator and the rotor magnet are isolated by the partition wall, the magnetic sensor is arranged as far away from the rotor magnet as the partition wall thickness, so that the magnetic sensor magnetic pole detection accuracy may be reduced. Therefore, it is suitable for improving the pump efficiency.

According to a thirteenth aspect of the present invention, according to any one of the tenth to twelfth aspects, a projection extending downward in the axial direction is formed on the bottom portion of the partition wall, and the circuit board is formed of the partition wall. A projection through hole is formed in a position facing the bottom portion in the axial direction and disposed below the bottom portion and facing the projection on the bottom portion of the circuit board. The circuit board is fixed by plastically deforming the protrusion through hole.

According to the fourteenth aspect of the present invention, the motor has a center coaxial with the rotation center axis, and has an annular core back portion and a diameter facing the rotation center axis away from the core back portion in the circumferential direction. A stator core composed of a plurality of teeth extending in a direction, an insulator that covers at least the teeth of the stator core and electrically insulates, and a plurality of conductors are wound through the insulator in the teeth. A stator having a coil formed by: a circuit board disposed axially opposite to the insulator and connected to a magnetic sensor; and the number of phases of the motor is two, and There is one magnetic sensor, and the insulator is provided with a sensor holder that accommodates at least a part of the magnetic sensor. And butterflies.

According to the fifteenth aspect of the present invention, there is provided a stator manufacturing method, an annular core back portion having a center coaxial with a rotation center axis, and fixed to the core back portion, and spaced apart in the circumferential direction. A shaft having a stator composed of a teeth portion extending toward the rotation center axis, and an annular ring formed on the inner peripheral side of the teeth portion that covers at least the teeth portion of the stator core and is electrically insulated. And a coil formed by winding a conductive wire around the tooth portion via the insulator, and a tooth unit unit for attaching the insulator from both sides in the axial direction of the tooth portion. A process, a coil forming process for forming the coil, and a fitting process for fixing the teeth part and the core back part. The features.

According to Claim 15 of this invention, each teeth part can be integrally hold | maintained with an insulator by the teeth part unit manufacturing process. Therefore, even if the tooth portion is not held by the core back portion, the tooth portion is held by the insulator, so that each tooth portion can be favorably disposed at a predetermined position in the circumferential direction. With this configuration, there is no need for a jig for separately holding each tooth portion. In addition, since the teeth portion can be held by the insulator and the conductive wire can be wound in this state, a nozzle for winding the conductive wire can be inserted from the outside in the radial direction. Accordingly, the degree of freedom of movement of the nozzles can be increased, so that the number of turns of the conductive wire wound around the tooth portion can be increased.

According to a sixteenth aspect of the present invention, according to the fifteenth aspect, in the coil forming step, the plurality of teeth portions are continuously wound by guiding the conductive wire to a circumferential surface of the annular ring. The plurality of coils are formed.

According to claim 16 of the present invention, since the insulator has an annular ring, the conductor is guided by the peripheral surface of the annular ring without cutting the conductor with respect to each tooth portion. A coil can be formed continuously. Further, by guiding the conducting wire to the circumferential surface of the annular ring, the annular ring and the conducting wire come into contact with each other with an appropriate tension during coil forming. Therefore, there is no large slack between the annular ring and the conductive wire guided on the peripheral surface thereof. Therefore, the lead wire can be prevented from coming into contact with other members due to the slack of the lead wire.

According to claim 17 of the present invention, according to any one of claims 15 and 16, in the vicinity of the fitting portion of the teeth portion that fits with the core back portion, the tooth portion extends in a direction substantially perpendicular to the radial direction. An extension is formed, and the insulator is formed with a cover that covers an inner peripheral surface of the extension.

According to claim 17 of the present invention, with this configuration, the cover portion of the insulator is guided by the extension portion of the tooth portion and formed along the extension portion of the tooth portion. Therefore, when the core back portion and the tooth portion are fixed, it is possible to prevent the insulator cover portion from interfering with the fixing. Therefore, since the operator can easily perform the core fitting process, the production efficiency of the brushless motor can be improved. Moreover, the contact between the coil and the core back portion can be prevented by forming the cover portion. Therefore, a highly reliable stator can be provided.

According to claim 18 of the present invention, there is provided a method for manufacturing a pump, comprising: a rotor having a rotor magnet that rotates along a rotation center axis; and an impeller that rotates integrally with the rotor magnet; and the rotation center. A stator core having a center coaxial with the shaft, and comprising a ring-shaped core back portion and a plurality of teeth portions circumferentially spaced from the core back portion and extending radially toward the rotation center axis; and An insulator for electrical insulation having a sensor holder that covers at least the tooth portion and accommodates at least a part of the magnetic sensor, and a plurality of conductive wires are wound around the tooth portion via the insulator. A stator having a coil, and an insulator that is disposed opposite to the insulator in an axial direction and connected to the magnetic sensor A lower case having a separated circuit board, a partition having a cylindrical part and a bottom part, separating the rotating part and the stator, and forming a pump chamber by combining with the lower case And an upper case having a drain port, a stator arrangement step of arranging the stator in the lower case, and a magnetic sensor accommodation step of accommodating the magnetic sensor in the sensor holder after the stator arrangement step, And a magnetic sensor connecting step of connecting the magnetic sensor to the circuit board after the magnetic sensor housing step.

According to an nineteenth aspect of the present invention, in accordance with the eighteenth aspect, a projection extending downward in the axial direction is formed at the bottom of the partition, and the circuit board is formed on the bottom of the partition. A projection through hole is formed in a position facing the bottom portion in the axial direction and disposed below the bottom portion and facing the projection on the bottom portion of the circuit board. Between the magnetic sensor accommodation step and the magnetic sensor connection step, a circuit board arranging step of passing the circuit board through the protrusion through-hole is further provided.

According to Claim 20 of the present invention, in accordance with Claim 19, the magnetic sensor is a Hall element having a plurality of legs, and the plurality of legs are provided at positions where the Hall elements are attached on the circuit board. A plurality of opening holes corresponding to the portion are formed, and the plurality of leg portions of the Hall element are passed through the plurality of opening holes of the circuit board between the circuit board arranging step and the magnetic sensor connecting step. The method further comprises a magnetic sensor attachment step, and a circuit board adjustment step for adjusting the circuit board in a radial direction and a circumferential direction after the magnetic sensor attachment step.

According to claim 18 to claim 20 of the present invention, a position where a load is not applied to the hall element by adjusting the circuit board by connecting the circuit board after accommodating the hall element as a magnetic sensor in the sensor holder. The circuit board can be adjusted. Therefore, a highly reliable pump can be provided.

ADVANTAGE OF THE INVENTION According to this invention, the magnetic pole detection of a Hall element can be performed accurately and a highly reliable brushless motor and the pump carrying this brushless motor can be provided.

<Overall structure of pump>
One embodiment of a pump according to the present invention will be described with reference to FIG. FIG. 1 is a schematic cross-sectional view of the pump 1 cut in the axial direction.

Referring to FIG. 1, the lower case 10 includes a bottomed cylindrical partition wall 11 disposed coaxially with the rotation center axis J1. The lower case 10 has a case cylindrical portion 12 that is formed to be radially separated from the partition wall 11 and is concentric with the center of the partition wall 11. The case cylindrical portion 12 becomes a part of the outer diameter of the pump 1. The lower case 10 is molded by injection molding a resin material.

A substantially cylindrical shaft fixing portion 11b is formed at a position concentric with the rotation center axis J1 of the bottom portion 11a of the partition wall 11 so as to extend upward in the axial direction. The outer peripheral surface of the shaft 14 is fixed in contact with the inner peripheral surface of the shaft fixing portion 11b. Thereby, the shaft 14 is arrange | positioned coaxially with the rotation center axis J1.

The upper case 20 is fixed to the upper surface of the lower case 10. Thereby, the space surrounded by the upper case 20 and the partition wall 11 becomes the pump chamber 30. The upper case 20 has a cylindrical inlet 21 through which water flows into the pump chamber 30 from the outside of the pump 1 and a cylindrical discharge port (not shown) through which water flows out of the pump 1 from the pump chamber 30. .

The pump chamber 30 is a rotor and accommodates an impeller 40 that circulates water in the pump chamber 30. The impeller 40 is formed by integrally forming a ferrite magnet, and includes a blade portion 41 that mainly circulates water and a magnetic drive portion 42 that rotates mainly by a magnetic action. . An inner peripheral cylindrical portion 41 a extending downward in the axial direction is formed on the inner peripheral surface of the blade portion 41. A substantially cylindrical bearing member 43 having an inner peripheral surface that slides with the outer peripheral surface of the shaft 14 is fixed to the inner peripheral surface of the inner peripheral cylindrical portion 41a. In addition, a through hole 41b penetrating in the axial direction is provided between the inner peripheral cylindrical portion 41a and the magnetic drive portion 42 in the radial direction. With this through hole 41b, the balance of the water pressure in the pump chamber 30 can be kept substantially constant. A plurality of the through holes 41b are provided at equal intervals in the circumferential direction.

The blade portion 41 of the impeller 40 has a shape extending in the radial direction from the partition wall 11. Accordingly, the upper case 20 is formed with an enlarged accommodating portion 22 for accommodating the blade portion 41. The blade portion 41 is accommodated between the upper surface of the lower case 10 and the enlarged accommodating portion 22 of the upper case 20. In the enlarged accommodating portion 22, a spiral water flow is formed by the rotation of the impeller 40.

The magnetic drive unit 42 has a substantially cylindrical shape, and has an outer circumferential surface that faces the inner circumferential surface of the cylindrical portion 11c of the partition wall 11 with a gap in the radial direction. Further, on the outer peripheral surface of the cylindrical portion 42a of the magnetic drive unit 42, N poles, S poles,..., And magnetic poles are magnetized in the circumferential direction.

The inlet 21 of the upper case 20 is provided with a bottomed cylindrical shaft holding portion 21 a that houses the upper portion of the shaft 14, and a connecting portion 21 b that connects the shaft holding portion 21 a and the inlet 21. A bearing member 43 is disposed between the shaft holding portion 21a of the upper case 20 and the shaft fixing portion 11a of the lower case 10 in the axial direction. The upper sliding member 50 is disposed so as to be sandwiched between the upper end surface of the bearing member 43 and the lower end surface of the shaft holding portion 21a. And the lower side sliding member 51 is arrange | positioned so that it may be pinched | interposed into the lower end surface of the bearing member 43, and the upper end surface of the shaft fixing | fixed part 11b. The upper sliding member 50 and the lower sliding member 51 are formed of a material having excellent slidability.

A stator 60 is fixed between the outer peripheral surface of the partition wall 11 of the lower case 10 and the inner peripheral surface of the case cylindrical portion 12. A step portion 12 a extending radially inward is formed on the upper side in the axial direction of the case cylindrical portion 12. And the position of the axial direction of the stator 60 is determined by this step part 12a.

A cylindrical projection 11d extending downward in the axial direction is formed on the bottom 11a of the partition wall 11 below the rotation center axis J1. A circuit board 70 having a projection through-hole 72 through which the projection 11d passes is disposed on the lower side in the axial direction so as to face the bottom portion 11a in the axial direction. A Hall element 71 that is a magnetic sensor is fixed to the upper surface of the circuit board 70 so as to face the outer peripheral surface of the magnetic drive unit 42 of the impeller 40 in the radial direction. The projection 11d is formed with a step portion 11d1 that forms a portion that is smaller than the inner diameter of the projection through-hole 72 and is inserted into the projection through-hole 72 and a portion that is larger than the inner diameter of the projection through-hole 72.

When an electric current is passed through the stator 60 from an external power source (not shown), a magnetic field is formed in the stator 60. A magnetic circuit is formed between the magnetic drive unit 42 and the stator 60, and torque is generated in the impeller 40 around the rotation center axis J <b> 1. Thereby, the impeller 40 rotates and a water flow is formed in the pump chamber 30.

<Stator structure>
Next, the structure of the stator 60 of the present invention will be described with reference to FIGS. FIG. 2 shows a top view of the stator 60. FIG. 3 is a perspective view of the stator 60 with the coil 63 removed. FIG. 4 shows the sensor holder 62a3, in which a) is a plan view of the sensor holder 62a3 as viewed from above, and b) is a schematic cross-sectional view cut in the axial direction. FIG. 5 is a view seen from the bottom 11 a side of the partition wall 11 when the partition wall 11 of the lower case 10 is inserted into the stator 60. FIG. 6 is a flowchart showing a manufacturing process of the stator 60.

2 and 3, the stator 60 includes an annular core back portion 61 a on the outer peripheral side and four teeth portions 61 b that are arranged at equal intervals of 90 degrees in the circumferential direction and extend radially inward. A stator core 61, two insulators 62 covering the stator core 61 from both sides in the axial direction, and a coil 63 formed by winding a conductive wire 63 a via the insulator 62 in the tooth portion 61 b (in this embodiment, 4).

The stator core 61 is formed by laminating a plurality of thin magnetic plates in the axial direction. The insulator 62 is formed by injection molding a resin material having electrical insulation. The coil 63 is so-called concentrated winding that is wound around each of the tooth portions 61b to form a coil. The conductive wire 63a of the coil 63 is formed of a copper wire covered with an insulating film.

Further, the stator 60 of the present invention is constituted by two phases. By setting the stator 60 to two phases, the number of electronic components required to be used for rotor rotation control can be reduced as compared to the three phases. Therefore, an inexpensive pump can be provided.

On the inner peripheral side of the tooth portion 61b in the stator core 61, a circumferential extension 61b1 extending on both sides in the circumferential direction is formed. The inner peripheral surface of the circumferential extension 61b1 faces the outer peripheral surface of the magnetic drive unit 42 in the radial direction. An extension 61b2 extending perpendicularly to the teeth 61b and a fitting protrusion 61b3 further extending in the radial direction from the extension 61b2 are formed on the outer peripheral side of the teeth 61b.

In addition, a planar inner peripheral surface that engages with the extension portion 61b2 is formed at a portion of the inner peripheral surface of the core back portion 61a that faces the extension portion 61b2 in the radial direction. And the fitting recessed part 61a1 fitted with the fitting protrusion 61b3 of the teeth part 61b is formed in this inner peripheral surface. Moreover, in the inner peripheral surface of the core back part 61a, the part which connects each plane is formed in a curved surface.

The insulator 62 includes two members, a lower insulator 62a and an upper insulator 62b (see FIG. 3). The lower insulator 62a and the upper insulator 62b cover the upper and lower sides in the axial direction of the tooth portion 61b, respectively. The lower insulator 62a has substantially the same shape as the upper insulator 62b. Therefore, here, the lower insulator 62a will be described.

An outer cover portion 62a1 that contacts the inner peripheral surface of the extension portion 61b2 of the tooth portion 61b and extends radially outward to contact the inner peripheral surface of the core back portion 61a is formed on the outer peripheral portion of the lower insulator 62a. . When the outer cover portion 62a1 comes into contact with the inner peripheral surface of the extension portion 61b2, the outer cover portion 62a1 is deformed radially inward by the extension portion 61b2 and has a shape extending in the circumferential direction. Accordingly, it is possible to prevent the outer cover portion 62a1 from interfering when the teeth portion 61b and the core back portion 61a are fitted. Therefore, the operator can easily perform the fitting operation between the tooth portion 61b and the core back portion 61a. As a result, productivity in manufacturing the stator 60 can be improved.

A substantially ring-shaped annular ring 62a2 is formed on the inner peripheral portion of the lower insulator 62a on the upper side in the axial direction along the inner peripheral edge of the tooth portion 61b. A portion of the insulator covering each tooth portion 61b is connected by the annular ring 62a2 to form an integral member. In this manner, the lower insulator 62a is not formed for each tooth portion 61b, but is formed into a shape in which all the tooth portions 61b are connected, so that the lower insulator 62a is separated from each tooth portion 61 by a separate member. In the case of molding with, four lower insulators are required, but one member can be formed. Therefore, the number of parts can be reduced.

A sensor holder 62a3 that accommodates the Hall element 71 is formed at a position between the circumferentially extending portions 61b1 of the teeth portions 61ba and 61bb adjacent in the circumferential direction of the annular ring 62a2. By forming the sensor holder 62a3 integrally with the annular ring 62a2, the circumferential position of the sensor holder 62a3 is determined depending on the range of the molding error of the lower insulator 62a. Therefore, the circumferential position of the sensor holder 62a3 with respect to each of the tooth portions 61ba and 61bb can be determined with high accuracy. As a result, the circumferential position of the Hall element 71 accommodated in the sensor holder 62a3 with respect to the tooth portions 61ba and 61bb can be determined easily and with high accuracy.

Here, the sensor holder 62a3 is not necessarily formed between the circumferential directions of the circumferentially extending portions 61b1 of the adjacent tooth portions 61b. The sensor holder 62a3 may be formed at a position shifted in the circumferential direction from between the circumferential directions of the circumferentially extending portion 61b1 depending on characteristics desired by the Hall element 71, such as the advance angle and the delay angle in the Hall element 71.

Further, a radial protrusion 62a4 is formed at the center in the circumferential direction of each tooth portion 61b of the lower insulator 62a. An opening hole 62a5 penetrating toward the tooth portion 61b is formed on the upper surface of the radial protrusion 62a4. A binding pin 64 formed of a conductive material is fixed to the opening hole 62a5 (see FIG. 2). In particular, the binding pin 64 in the present embodiment is fixed by being press-fitted into the opening hole 62a5.

In addition, circumferential recesses 62a6 that are concave toward the outside in the radial direction are formed at positions equally spaced 90 degrees in the circumferential direction from the sensor holder 62a3.

Referring to FIG. 4A, the sensor holder 62a3 has a concave shape toward the radially outer side on the inner peripheral surface of the annular ring 62a2. Of the inner peripheral surface of the sensor holder 62a3, the inner surface 62a31 that is farthest in the radial direction from the rotation center axis J1 is formed by a plane that is perpendicular to the radial direction. In addition, an inclined surface 62a32 is formed on the circumferential surface extending radially inward from both circumferential sides of the inner surface 62a31 of the sensor holder 62a3 (the circumferential surface of the circumferential direction is reduced by the inclined surface 62a32). A portion where the width is reduced is defined as a reduced width portion). The circumferential width of the opening 62a33, which is the innermost radial direction of the sensor holder 62a3, is the smallest of the circumferential widths of the sensor holder 62a3. The circumferential width of the opening 62 a 33 of the sensor holder 62 a 3 is formed to be equal to the circumferential width of the Hall element 71 or smaller than the circumferential width of the Hall element 71.

Further, a projection 62a34 extending radially inward is formed on the inner surface 62a31. The inner surface of the protrusion 62 a 34 is in contact with the Hall element 71. With reference to b) of FIG. 4, the upper part of protrusion 62a34 continues through back surface 62a31 and an inclined surface. This inclined surface makes it easier to accommodate the Hall element 71 in the sensor holder 62a3. In addition, the sensor holder 62a3 is formed with a bottom surface 62a35 that faces an end surface in the axial direction of the Hall element 71 (end surface in the accommodation direction of the Hall element). A recess 62a36 that is recessed downward in the axial direction is formed around the protrusion 62a34 on the bottom surface 62a35. The concave portion 62a36 can eliminate the curved surface formed when the protrusion 62a34 and the bottom surface 62a35 are connected. Therefore, the Hall element 71 can be accommodated with high accuracy without tilting in the radial direction.

Moreover, the upper end part of protrusion 62a34 and the back surface 62a31 are connected by the inclined surface 62a37. The inclined surface 62a37 is inclined radially inward and upward. Thus, when the Hall element 71 is inserted into the sensor holder 62a3 from above, the inclined surface 62a37 can favorably guide the radial position of the Hall element 71.

Next, with reference to FIG. 5, the relationship between the peripheral surface recessed part 62a6 and the partition 11 of the lower case 10 is demonstrated.

In the partition wall 11, ribs 11 a 1 are formed at intervals of 90 degrees in the circumferential direction to increase the radial thickness of the cylindrical portion 11 c toward the radially outer side centering on the protrusion 11 d formed on the bottom portion 11 a. The rib 11a1 is also formed integrally with the cylindrical portion 11c. Moreover, it is desirable that the circumferential width of the rib 11a1 is equal to the circumferential gap between the circumferentially extending portions 61b1 of the adjacent tooth portions 61b. With such a relationship, the circumferential position of the stator 60 can be determined by the rib 11a1. Further, it can also serve as a circumferential stop for the lower case 10 of the stator 60.

The radial thickness of the cylindrical portion 11c of the partition wall 11 is set as much as possible in order to narrow the radial gap between the outer peripheral surface of the magnetic drive unit 42 and the inner peripheral surface of the tooth portion 61b for the purpose of improving magnetic efficiency. It is desirable to be thin (in the present embodiment, the thickness of the cylindrical portion 11c is about 0.4 mm). However, if the cylindrical portion 11c is formed with a small thickness in the radial direction, the flow of the resin material in the mold when the cylindrical portion 11c of the partition wall 11 of the lower case 10 is formed deteriorates, resulting in frequent molding defects. There is a problem. However, since the rib 11a1 is formed on the cylindrical portion 11c, the rib 11a1 can prevent deterioration of the flow of the resin material in the mold. Therefore, molding defects can be reduced. As a result, it is possible to achieve the lower case 10 having the partition wall 11 with reduced molding defects while making the cylindrical portion 11c as thin as possible.

Moreover, since the intensity | strength of the cylindrical part 11c will become weak when the thickness of the radial direction of the cylindrical part 11c is thin, it will become easy to transmit the vibration which the stator 60 generate | occur | produces. However, since the strength of the cylindrical portion 11c can be improved by forming the ribs 11a1, transmission of vibrations generated by the stator 60 can be suppressed.

Further, it is desirable that the rib 11a1 is not formed on the cylindrical portion 11c corresponding to the sensor holder 62a3. Generally, it is desirable that the Hall element 71 is as close to the outer peripheral surface of the magnetic drive unit 42 as possible in the radial direction in order to detect the magnetic flux from the magnetic drive unit 42. However, if the rib 11a1 is provided at the position of the cylindrical part 11c corresponding to the sensor holder 62a3, the radial distance between the Hall element 71 and the magnetic drive part 42 becomes large. As a result, the magnetic detection capability of the Hall element 71 may be reduced. Therefore, in this embodiment, the rib 11a1 is not provided at the position of the cylindrical portion 11c corresponding to the sensor holder 62a3 in which the Hall element 71 is accommodated.

A circumferential recess 62a6 of the insulator 62 is disposed at a position corresponding to the rib 11a1 of the cylindrical portion 11c. The circumferential width of the circumferential recess 62a6 and the circumferential width of the rib 11a1 are substantially the same, and the rib 11a1 is disposed in the circumferential recess 62a6. Thereby, the rib 11a1 can play the role of the rotation prevention of the circumferential direction of the stator 60 more efficiently.

<Manufacturing method of stator>
Next, a method for manufacturing the stator 60 will be described with reference to FIG.

The four insulators 61b are covered with the lower insulator 62a and the upper insulator 62b (step S10 in FIG. 6). In this state, the binding pin 64 is fixed to the opening hole 62a5 of the radial protrusion 62a4 of the lower insulator 62a. First, the conductive wire 63a is wound around the binding pin 64 of the predetermined tooth portion 61b. At this time, a part of the insulating film at the tip of the conductive wire 63a is peeled off and fixed to the binding pin 64 with the copper wire exposed.

Next, the conductive wire 63a is wound around a predetermined tooth portion 61b to form the coil 63 (step S11 in FIG. 6). By winding the conductive wire 63a around the tooth portion 61b in a state of being fixed to the binding pin 64 in advance, it can be wound with a certain tension.

And after formation of the coil 63 to one teeth part 61b is complete | finished, it moves to the teeth part 61b on the 180 degree opposite side (step S12 of FIG. 6). The movement of the conductive wire 63a between the teeth 61b moves in contact with the outer peripheral surface of the annular ring 62a2. In particular, the conductive wire 63a moves in contact with the outer peripheral surface of the sensor holder 62a3.

Next, the coil 63 is formed by winding the conductive wire 63a around the tooth portion 61b on the opposite side of 180 degrees (step S13 in FIG. 6). And after forming the coil 63 in the teeth part 61b, a part insulation film of the front-end | tip of the conductive wire 63a is peeled off to the binding pin 64, and it fixes in the state which exposed the copper wire. In addition, since the two conductive wires 63a are used, the steps from Step S11 to Step 13 in this embodiment are performed again with respect to the different tooth portions 61b.

Finally, the core back part 61a is fitted and fixed to the outer peripheral part of the tooth part 61b (step S14 in FIG. 6).

A winding nozzle (not shown) for supplying the conductive wire 63a by manufacturing the stator 60 by the above-described process, and in particular by having the process of fixing the four tooth portions 61b by the insulator 62 (step S10 in FIG. 6). However, it can insert from the outer peripheral surface of the adjacent teeth part 61b. In particular, in the stator 60 having a shape in which the tooth portion 61b extends radially inward as in the present embodiment and the core back portion 61a is fixed to the outer peripheral portion of the tooth portion 61b, the stator 61b is adjacent to the inner peripheral surface of the tooth portion 61b. The gap between the teeth 61b is reduced. When the winding nozzle is inserted from the inner peripheral side of the tooth portion 61b having a small gap and the conductive wire 63a is wound, the movement of the winding nozzle moves between the gap between the inner peripheral surfaces of the adjacent tooth portions 61b. Become. Therefore, the movement of the winding nozzle in the circumferential direction is greatly limited. As a result, since the winding nozzle needs to be moved very carefully, the winding speed and the moving speed of the winding nozzle become slow. However, by inserting the winding nozzle from the outer peripheral side of the tooth portion 61b as in this embodiment, the gap between the adjacent tooth portions 61b is increased on the outer peripheral side of the tooth portion 61b. There are no significant restrictions on circumferential movement. Therefore, it can be easily wound around the teeth portion 61b. As a result, the speed at which the conductive wire 63a is wound around the tooth portion 61b and the speed at which the winding nozzle moves can be improved. In addition, since there is no significant restriction on the movement of the winding nozzle, the number of windings of the conductive wire 63a around the tooth portion 61b can be increased. Therefore, the characteristics of the motor can be improved. In addition, since the width in the circumferential direction of the inner peripheral surface of the adjacent tooth portions 61b can be increased, the characteristics of the motor can be improved.

Further, since the annular ring 62a2 is formed in the insulator 62, the conductive wire 63a can be easily routed between the tooth portions 61. In addition, since the conductive wire 63a is guided by the peripheral surface of the annular ring 62a2, the coil 63 can be continuously formed without cutting the conductive wire 63a with respect to each tooth portion 61b. Further, by guiding the conductive wire 63a to the peripheral surface of the annular ring 62a2, the peripheral surface of the annular ring 62a2 and the conductive wire 63a come into contact with an appropriate tension when the coil 63 is formed. Therefore, the conductive wire 63a guided by the circumferential surface of the ring 62a2 does not have a large slack. Therefore, it is possible to prevent the conductive wire 63a from coming into contact with other members due to the slack of the conductive wire 63a.

<Hall element and circuit board>
Next, the configurations of the Hall element 71 and the circuit board 70 will be described with reference to FIGS. FIG. 7 is a perspective view showing the Hall element of this embodiment. FIG. 8 is a schematic plan view showing the circuit board of the present embodiment as viewed from above. FIG. 9 shows a guide member 80 attached to the Hall element, in which a) is a plan view seen from above, and b) is a schematic cross-sectional view cut in the axial direction.

Referring to FIG. 7, the Hall element 71 includes a detection unit 71 a that detects the magnetic flux of the magnetic drive unit 42, and a plurality of legs 71 b for connecting the detection unit 71 a and the circuit board 70 (in this embodiment, 3). The detector 71a is formed in a substantially rectangular shape.

With reference to FIG. 8, the circuit board 70 is formed with a projection through-hole 72 through which the projection 11 d of the partition wall 11 of the lower case 10 passes. The inner diameter of the protrusion through-hole 72 is formed larger than the outer diameter of the portion of the protrusion 11d through which the circuit board 70 passes. Further, through holes 73 (three in this embodiment) larger than the outer diameter of the leg portion 71b are formed at positions corresponding to the leg portion 71b of the hall element 71. The Hall element 71 and the circuit board 70 are fixed by solder on the surface opposite to the side where the leg portion 71 b is inserted into the through hole 73.

A pin through hole 74 is formed at a position corresponding to the binding pin 64 on the circuit board 70. The inner diameter of the pin through hole 74 is formed larger than the outer diameter of the binding pin 64.

Referring to FIG. 9, guide member 80 is formed by injection molding a resin material. The guide member 80 is formed with a through hole 81 through which the leg portion 71b of the hall element 71 is inserted. A circumferential surface 82 in which one of the four surfaces is opened is formed on the upper side in the axial direction of the through hole 81. The opened one surface faces the magnetic drive unit 42 in the radial direction.

Further, the circumferential width of the circumferential surface 82 is formed larger than the circumferential width formed by the plurality of legs 71 b of the Hall element 71. The peripheral surface 82 is adjacent to the leg portions 71b on both sides in the circumferential direction. Thereby, even if the leg portion 71b is bent, it can be supported by the peripheral surface 82. Therefore, it is possible to prevent the leg portion 71b from being bent extremely. Therefore, cutting of the leg portion 71b can be prevented.

Referring to FIG. 9b), the through hole 81 is formed with an inclined surface 81a having a smaller inner diameter toward the lower side in the axial direction. And the internal diameter of the lower part of the through-hole 81 becomes substantially the same as the outer diameter of each leg part 71b. Therefore, it is possible to achieve the guide member 80 having the through hole 81 that can be easily inserted through the leg portion 71b of the Hall element 71 and can be reliably held.

<Attaching method of stator and circuit board>
Next, a method of attaching the stator 60 and the circuit board 70 according to the present invention will be described with reference to FIG. FIG. 10 is a flowchart showing a process of attaching the stator 60 and the circuit board 70.

First, the hall element 71 is accommodated in the sensor holder 62a3 of the insulator 62 of the stator 60 (step S20 in FIG. 10). Only the detector 71a is accommodated in the sensor holder 62a3. The leg portion 71b protrudes in the axial direction from the sensor holder 62a3.

Next, the stator 60 and the circuit board 70 are connected (step S21 in FIG. 10). At this time, the guide member 80 may be fixed to the circuit board 70 in a position corresponding to the through hole 73 of the circuit board 70 in advance. In this state, the leg portions 71b of the hall element 71 are inserted through the through holes 81 of the guide member 80, respectively. Further, the entangled pins 64 are respectively inserted into the pin through holes 74.

Next, the radial position and the circumferential position of the circuit board 70 are adjusted so that the leg portion 71b of the Hall element 71 is not deformed (step S22 in FIG. 10). Thereby, since it is possible to prevent the permanent stress from being applied to the leg portion 71b, the reliability can be improved.

Finally, the hall element 71 is connected to the circuit board 70 by depositing solder around the leg 71b of the hall element 71 protruding from the circuit board 70 and the periphery thereof (step S23 in FIG. 10). In addition, the binding pin 64 is connected to the circuit board 70 by depositing solder around the binding pin 64 and the periphery of the circuit board 70.

<Pump manufacturing method>
Next, the manufacturing method of the pump 1 of this invention is demonstrated with reference to FIG. FIG. 11 is a flowchart showing a method for manufacturing the pump 1.

First, the stator 60 is disposed in the radial gap between the outer peripheral surface of the partition wall 11 and the inner peripheral surface of the case cylindrical portion 12 in the lower case 10 (step S30 in FIG. 11). The center of the stator 60 and the center of the lower case 10 are adjusted by bringing the inner peripheral surface of the tooth portion 61 b of the stator 60 into contact with the outer peripheral surface of the partition wall 11. Thereby, the radial gap between the outer peripheral surface of the magnetic drive portion 42 of the impeller 40 and the inner peripheral surface of the tooth portion 61b can be reduced.

Further, the rib 11a1 formed in the cylindrical portion 11c of the partition wall 11 of the lower case 10 is inserted with the circumferential gap of the circumferentially extending portion 61b1 of the adjacent tooth portion 61b and the circumferentially recessed portion 62a6 of the insulator 62 in the stator 60. . Accordingly, the circumferential position of the stator 60 with respect to the lower case 10 is determined.

In addition, the axial end surface of the core back portion 61 a of the stator 60 is in contact with the stepped portion 12 a provided in the case cylindrical portion 12. Thereby, the axial position of the stator 60 with respect to the lower case 10 is determined.

Next, the inspection portion 71a of the Hall element 71 is accommodated in a space surrounded by the sensor holder 62a3 formed in the insulator 62 and the outer peripheral surface of the partition wall 11 (step S31 in FIG. 11). At this time, the guide member 80 may be fixed to the circuit board 70 in a position corresponding to the through hole 73 of the circuit board 70 in advance. In this state, the leg portions 71b of the hall element 71 are inserted through the through holes 81 of the guide member 80, respectively. Further, the entangled pins 64 are respectively inserted into the pin through holes 74. In this state, the leg 71b of the Hall element 71 protrudes in the axial direction from the sensor holder 62a3 and the bottom 11a of the partition wall 11.

Next, the circuit board 70 is disposed below the bottom 11a of the lower case 10 (step S32 in FIG. 11). More specifically, a part of the protrusion 11 d of the partition wall 11 is inserted inside the protrusion through hole 72 of the circuit board 70. Then, the position of the circuit board 70 in the axial direction with respect to the partition wall 11 is determined by contacting the periphery of the protrusion through-hole 72 and the upper surface of the step portion 11d1.

Next, the radial position and the circumferential position of the circuit board 70 are adjusted so that the leg 71b of the Hall element 71 is not deformed (step S33 in FIG. 11). Thereby, since it is possible to prevent the permanent stress from being applied to the leg portion 71b, the reliability can be improved. The hall element 71 is connected to the circuit board 70 by depositing solder around the leg 71 b of the hall element 71 protruding from the circuit board 70 and the periphery thereof. In addition, the binding pin 64 is connected to the circuit board 70 by depositing solder around the binding pin 64 and the periphery of the circuit board 70.

Further, the circuit board 70 is fixed to the partition wall 11 by thermally welding a portion of the protrusion 11d of the partition wall 11 that protrudes from the surface opposite to the projection 11d of the circuit board 70 (step S34 in FIG. 11). Further, the circuit board 70 and the lower case 10 are provided with protrusions extending downward in the axial direction on the outer peripheral side of the lower case 10. A through hole is provided at a position corresponding to the protrusion of the circuit board 70. The circuit board 70 and the protrusion of the lower case 10 are fixed by a fixing member such as a bolt.

The shaft 14 is fixed to the shaft fixing portion 11b of the lower case 10 coaxially with the rotation center axis J1. Further, the shaft 14 may be fixed to the lower case 10 in advance.

Next, the impeller 40 is disposed so as to be substantially coaxial with the shaft 14 (step S35 in FIG. 11). Then, the upper case 20 is attached to the lower case 10 (step S36 in FIG. 11).

<Other embodiments>
Another embodiment of the sensor holder according to the present invention will be described with reference to FIG. FIG. 12 is a schematic cross-sectional view taken along the axial direction showing the relationship between the case having the partition and the circuit board in the pump having the partition between the impeller and the stator.

Referring to FIG. 12, sensor holder 100 is formed on the outer peripheral surface of cylindrical portion 111 a in partition 111 of case 110. Further, on the upper side in the axial direction of the sensor holder 100, a peripheral rib 101 extending toward the radial extension 112 of the case 110 is integrally formed. The circumferential rib 101 is formed with a circumferential width equal to or smaller than the circumferential width of the sensor holder 100 or smaller than the circumferential width of the sensor holder 100. Further, the circumferential position of the sensor holder 100 with respect to the tooth portion is easily determined by arranging the circumferential rib 101 in the circumferential gap on the inner circumferential surface of the tooth portion (not shown) adjacent in the circumferential direction. be able to.

As mentioned above, although the form of the Example of this invention was described, this invention is not limited to the said Example, A various deformation | transformation is possible within a claim.

For example, in the present embodiment, the number of Hall elements 71 is one, but the present invention is not limited to this. You may use two or more as needed. Sensor holders are respectively formed on the insulator according to the number of the Hall elements 71.

For example, in the present embodiment, the case where the stator 60 is mounted on the pump 1 has been described, but the present invention is not limited to this. The present invention can be applied to a general motor using a magnetic sensor such as a Hall element. The present invention can also be applied to a blower using a magnetic sensor such as a Hall element.

For example, in the present embodiment, the lower insulator 62a and the upper insulator 62b constituting the insulator 62 have the same shape, but the present invention is not limited to this. The lower insulator and the upper insulator do not necessarily have the same shape. For example, the upper insulator does not need to be provided with a sensor holder.

For example, in this embodiment, the impeller 40 is integrally formed of a ferrite material, but the present invention is not limited to this. Only the magnetic drive unit 42 may be formed of a ferrite material. That is, a configuration in which the magnet is fixed at the position of the magnetic drive unit 42 of the impeller 40 may be employed. Further, the material is not limited to the ferrite material, and may be any material generally used for magnet forming. In this embodiment, the rotor is the impeller 40 including the bearing portion 43. However, in the structure in which the magnet is separately fixed, the impeller 40 including the bearing portion 43 and the magnet constitute the rotor. In this case, it is desirable to insert-mold the shaft 14, the bearing portion 43, the impeller 40 and the rotor including the magnet formed separately from the impeller 40 into a mold (not shown). In particular, the impeller 40 is a resin material. In this case, if the entire impeller 40 is made of a material to be magnet-molded, the price of the impeller 40 increases. However, it is possible to prevent the price of the impeller 40 from rising by using only the magnetic drive unit 42 as a magnet and molding the impeller 40 with a magnet material only in a portion where the magnet is necessary. Further, by performing insert molding of the bearing portion 43 and the magnet with a resin material, there is no seam at the portion where the bearing portion 43 and the magnet and the impeller portion 40 are connected, so that it is possible to prevent water from entering from the seam. . Therefore, it is possible to provide a highly reliable motor and pump in which the magnet, the bearing portion 43, and the impeller portion 40 do not peel off.

It is the schematic cross section cut in the axial direction which showed one form of the Example of the pump of this invention. It is the model top view which looked at the stator of this invention from the upper surface. It is the perspective view which deleted the coil in the stator of this invention. The sensor holder of the insulator of this invention is shown, a) is the enlarged view which expanded the circumference | surroundings of the sensor holder of FIG. 2, b) is the schematic cross section which cut the sensor holder in the axial direction. It is the top view seen from the bottom side of a partition in the state where the stator and partition of the present invention were assembled. It is the flowchart which showed the manufacturing process of the stator of this invention. It is a perspective view of a Hall element. It is the model top view which looked at the circuit board of this invention from the upper surface. The guide member of this invention is shown, a) is the model top view seen from the upper surface, b) is the model cross section cut in the axial direction. It is the flowchart which showed the assembly method of the stator and circuit board of this invention. It is the flowchart which showed the manufacturing process of the pump of this invention. It is the schematic cross section cut in the axial direction which showed embodiment of the other sensor holder of this invention. It is the schematic cross section which cut the axial direction which showed the conventional pump.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Lower case 11 Partition 11a1 Rib 11c Cylindrical part 11d Protrusion 20 Upper case 30 Pump chamber 40 Impeller part 42 Magnetic drive part (rotor magnet)
60 Stator 61 Stator Core 61a Core Back 61b Teeth 62 Insulator 62a Ring 62a3 Sensor Holder 62a5 Opening Hole 63 Coil 64 Tying Pin 70 Circuit Board 71 Hall Element (Magnetic Sensor)

Claims (20)

A motor,
A stator core having a center coaxial with the rotation center axis, and comprising an annular core back portion and a plurality of teeth portions spaced radially from the core back portion and extending radially toward the rotation center axis;
An insulator having an annular ring that covers at least the teeth portion of the stator core and is electrically insulated, and is connected to the inner peripheral side of the teeth portion in the circumferential direction;
A coil formed by winding a plurality of conductive wires through the insulator in the teeth portion;
A stator having
A circuit board disposed axially opposite the insulator and mounted with a magnetic sensor;
With
The motor, wherein the annular ring of the insulator is provided with a sensor holder in which at least a part of the magnetic sensor is accommodated. The motor according to claim 1,
The motor according to claim 1, wherein the sensor holder has a concave shape in which an inner peripheral surface of the annular ring is recessed outward in the radial direction. The motor according to claim 2,
The sensor holder has a reduced width portion in which a width in a circumferential direction becomes narrower toward a radially inner side. A motor according to any one of claims 1 to 3,
The motor is characterized in that the inner surface, which is the inner circumferential surface farthest from the central axis of the sensor holder, has a planar shape extending in a direction perpendicular to the radial direction. The motor according to claim 4,
A protrusion extending outward in the radial direction is formed on the inner surface of the sensor holder,
The motor, wherein the protrusion and the magnetic sensor are in contact with each other. The motor according to claim 5,
The sensor holder is formed with a bottom surface facing the axial end surface of the magnetic sensor,
The motor according to claim 1, wherein a recess recessed downward is formed around the protrusion in the bottom surface. The motor according to any one of claims 1 to 6,
The magnetic sensor is a Hall element,
The Hall element has a plurality of legs connected to the circuit board,
The motor is characterized in that a guide member having a plurality of through holes through which the legs are passed is attached to the legs. The motor according to claim 7,
The guide member is attached to the circuit board,
The plurality of through-holes of the guide member each have an inclined surface whose diameter increases as the distance from the circuit board increases. A motor according to any one of claims 7 and 8,
A motor having a peripheral wall that covers at least both sides of the plurality of leg portions of the Hall element is formed above the through hole in the guide member. A pump,
A rotor magnet that rotates along the rotation axis;
A rotor having an impeller that rotates integrally with the rotor magnet;
A stator core having a center coaxial with the rotation center axis, and comprising a ring-shaped core back portion and a plurality of teeth portions circumferentially spaced from the core back portion and extending radially toward the rotation center axis;
An insulator that covers at least the teeth portion of the stator core and electrically insulates;
A coil formed by winding a plurality of conductive wires through the insulator in the teeth portion;
A stator having
A circuit board which is arranged opposite to the insulator in the axial direction and to which a magnetic sensor is connected;
A lower case having a partition having a cylindrical portion and a bottom portion, separating the rotating portion and the stator;
An upper case having a water inlet and a water outlet, which forms a pump chamber in combination with the lower case;
With
The pump, wherein the insulator is formed with a sensor holder that accommodates at least a part of the Hall element. The pump according to claim 10, wherein
The insulator has an annular ring formed on the inner peripheral side of the teeth portion,
The sensor holder is formed on an inner peripheral surface of the annular ring,
The pump, wherein the sensor holder faces the cylindrical portion of the partition wall in a radial direction. A pump according to any one of claims 10 and 11,
The sensor holder is formed in a concave shape that dents the annular ring radially outward,
An inner peripheral opening of the sensor holder is closed by an outer peripheral surface of the partition wall. The pump according to any one of claims 10 to 12,
A projection extending downward in the axial direction is formed on the bottom of the partition wall,
The circuit board is opposed to the bottom of the partition wall in the axial direction, and is disposed below the bottom.
A protrusion through-hole through which a part of the protrusion is passed is formed at a position facing the protrusion at the bottom of the circuit board,
The pump, wherein the circuit board is fixed by plastically deforming the projection through hole. A motor,
A stator core having a center coaxial with the rotation center axis, and comprising an annular core back portion and a plurality of teeth portions spaced radially from the core back portion and extending radially toward the rotation center axis;
An insulator that covers at least the teeth portion of the stator core and electrically insulates;
A coil formed by winding a plurality of conductive wires through the insulator in the teeth portion;
A stator having
A circuit board which is arranged opposite to the insulator in the axial direction and to which a magnetic sensor is connected;
With
The number of phases of the motor is 2, and the magnetic sensor is one,
The motor, wherein the insulator is provided with a sensor holder in which at least a part of the magnetic sensor is accommodated. A method for manufacturing a stator, comprising:
A stator composed of an annular core back portion having a center coaxial with the rotation center axis, and a tooth portion fixed to the core back portion and spaced apart in the circumferential direction and extending toward the rotation center axis;
An axially divided insulator having an annular ring formed on the inner peripheral side of the teeth portion, covering at least the teeth portion of the stator core and electrically insulating;
A coil formed by winding a conductive wire on the teeth portion via the insulator;
With
From both sides of the teeth portion in the axial direction, a teeth portion unit manufacturing step for attaching the insulator,
A coil forming step of forming the coil;
A fitting step for fixing the teeth portion and the core back portion;
A method for manufacturing a stator, comprising: A stator manufacturing method according to claim 15, comprising:
The coil forming step is characterized in that the plurality of teeth portions are continuously wound to form the plurality of coils by guiding the conducting wire to the peripheral surface of the annular ring. Method. A stator manufacturing method according to any one of claims 15 and 16, comprising:
An extension portion extending in a direction substantially perpendicular to the radial direction is formed in the vicinity of the fitting portion that fits with the core back portion of the teeth portion,
The insulator is formed with a cover portion that covers an inner peripheral surface of the extension portion. A method for manufacturing a pump, comprising:
A rotor magnet that rotates along the rotation axis;
A rotor having an impeller that rotates integrally with the rotor magnet;
A stator core having a center coaxial with the rotation center axis, and comprising a ring-shaped core back portion and a plurality of teeth portions circumferentially spaced from the core back portion and extending radially toward the rotation center axis;
An electrically insulating insulator having a sensor holder that covers at least the teeth portion of the stator core and accommodates at least a part of the magnetic sensor;
A stator having a coil formed by winding a plurality of conductive wires through the insulator in the teeth portion;
A circuit board disposed axially opposite the insulator and connected to the magnetic sensor;
A lower case having a partition having a cylindrical portion and a bottom portion, separating the rotating portion and the stator;
An upper case having a water inlet and a water outlet, which forms a pump chamber by being combined with the lower case, and
A stator arrangement step of arranging the stator in the lower case;
After the stator arrangement step, a magnetic sensor housing step of housing the magnetic sensor in the sensor holder;
After the magnetic sensor housing step, a magnetic sensor connection step for connecting the magnetic sensor to the circuit board;
A method for producing a pump, comprising: A method of manufacturing a pump according to claim 18,
A protrusion extending downward in the axial direction is formed on the bottom of the partition wall at the bottom of the partition wall,
The circuit board is opposed to the bottom of the partition wall in the axial direction, and is disposed below the bottom.
A protrusion through-hole through which a part of the protrusion is passed is formed at a position facing the protrusion at the bottom of the circuit board,
A method for manufacturing a pump, further comprising a circuit board arranging step of passing the circuit board through the protrusion through hole between the magnetic sensor housing step and the magnetic sensor connecting step. A method of manufacturing a pump according to claim 19,
The magnetic sensor is a Hall element having a plurality of legs,
A plurality of opening holes corresponding to the plurality of leg portions are formed at positions where the Hall elements are attached to the circuit board,
Between the circuit board placement step and the magnetic sensor connection step, a magnetic sensor attachment step of passing the plurality of leg portions of the Hall element through the plurality of opening holes of the circuit board;
A circuit board adjustment step of adjusting the circuit board in a radial direction and a circumferential direction after the magnetic sensor mounting step, further comprising a method for manufacturing a pump.

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