JP5006712B2 - Electric motor with reduction gear and manufacturing method thereof - Google Patents

Description

  The present invention relates to an electric motor with a reduction gear in which a motor main body and a reduction gear are formed as one unit, and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, as a drive source for a power window device, a sunroof device or the like provided in a vehicle, an electric motor with a speed reducer having a motor body and a speed reducer as a unit has been used, and the motor body has a brush and a commutator. In many cases, an electric motor with a brush that supplies current to an amateur coil is used.

  The electric motor with a brush includes a motor case (yoke) having a pair of magnets fixed on an inner peripheral surface, and an amateur having an armature shaft is rotatably accommodated in the motor case. The amateur is provided with a plurality of amateur coils, and a commutator (commutator) is fixed to the amateur shaft to supply current to these amateur coils, and a pair of brushes are attached to the brush holder attached to the motor case. Is retained. Each brush is in sliding contact with the outer circumference of the commutator, and when each brush is connected to the power source, current is supplied to each armature coil via the brush and the commutator at a predetermined timing, so that the amateur rotates. Yes.

  Such an electric motor is provided with a power feeding connector portion for connecting each brush to a power source. By connecting this connector portion to an external connector on the power source side, current is supplied to the brush. It has become.

For example, in Patent Document 1, a connector part for power feeding is formed integrally with a resin brush holder, the brush holder is sandwiched between an opening end of a motor case and a gear case of a reduction gear, and the connector part is fixed to a motor. An electric motor is described that protrudes from between the case and the gear case to the outside of the motor case.
JP 2001-346355 A

  In order to make an electric motor such as a power window motor compatible with a plurality of vehicle types, it is necessary to prepare a motor with a plurality of specifications with different connector specifications depending on the shape of the external connector provided on the vehicle body side and the insertion direction. .

  However, in the electric motor shown in Patent Document 1, since the connector portion is formed integrally with the brush holder from a resin material, a plurality of types of brushes having different connector portion specifications corresponding to the specifications of the external connector It is necessary to prepare a holder. Therefore, a plurality of molds corresponding to each brush holder must be prepared, and the cost of the electric motor with a speed reducer increases.

  Further, in order to integrally form the connector part and the brush holder, a large number of slide molds are required in addition to the upper and lower molds, and the shape of the mold for resin molding the brush holder is complicated, and the mold The mold itself becomes larger and the cost of the mold increases.

  An object of the present invention is to reduce the cost of an electric motor with a reduction gear by increasing the versatility of a brush holder for different specifications of a connector part.

An electric motor with a reduction gear according to the present invention is formed in a bottomed cylindrical shape having one end opened, and a motor case provided with a field part on an inner surface, and a brush mounted inside the motor case and holding a plurality of brushes A holder, one end rotatably supported by the motor case and the other end rotatably supported by the brush holder; and an end of the brush holder in the axial direction of the armature shaft. A plate-like base portion, a through-hole in which the armature shaft is inserted, a commutator fixed to the armature shaft and in sliding contact with the plurality of brushes, and connected to the commutator, respectively. A plurality of armature coils rotating together with the armature shaft and attached to the opening end of the motor case to close the opening of the motor case A gear case, a worm shaft that is rotatably accommodated in the gear case and connected to the armature shaft when the gear case is attached to the motor case, and a gear case that is rotatably accommodated and provided on the worm shaft a worm wheel meshing with the worm, is sandwiched and fixed the disposed to overlap in the axial direction against the brush holder and the motor case and the gear case, and provided on the outer side than the armature shaft in the radial direction of the armature shaft A connector unit including an annular sandwiching portion, a power feeding connector portion that is formed integrally with the sandwiching portion and disposed outside the motor case, and a plurality of power connection terminals provided in the connector portion; the provided in the brush holder, a plurality of bra to be electrically connected to the brush, respectively corresponding And the side connecting terminals provided in the connector unit, one end to said plurality of power supply connection terminals are arranged to overlap in the axial direction with respect to the clamping portion is electrically connected said base portion, respectively the other end to the plurality of brush-side connection terminals corresponding will have a plurality of connector-side connection terminals electrically connected to the case were, provided the holding portions to the open end of the motor case The flange portion and the gear case are clamped and fixed, and the other end portions of the plurality of connector side connection terminals are arranged inside the clamp portion in the radial direction of the armature shaft .

Reduction gear with electric motor of the present invention, said said axial end portion of the brush holder is brought into contact with the stepped portion provided on the inner surface of the motor case, and positioning the brush holder to the inside of the motor case, wherein A brush holder is clamped between the connector unit and the motor case.

  In the electric motor with a reduction gear according to the present invention, the side surface of the brush holder is press-fitted into the inner surface of the motor case and positioned inside the motor case, and the clamping part is supported by the motor case via the brush holder. It is characterized by that.

A method of manufacturing an electric motor with a speed reducer according to the present invention includes a motor case that is formed in a container shape having one end open and a field portion is fixed to an inner surface, and a brush that is mounted inside the motor case and holds a plurality of brushes A holder, a plurality of brush-side connection terminals provided on the brush holder and electrically connected to the corresponding brushes, one end rotatably supported on the motor case, and the other end on the brush holder An armature shaft that is rotatably supported, a base portion formed at an end portion of the brush holder in the axial direction of the armature shaft, a through-hole provided in the base portion and into which the armature shaft is inserted a commutator fixed to the armature shaft sliding contact with the brush, a plurality of a which rotates together with the armature shaft is connected to each of the commutator A step of manufacturing a motor body including a Chua coil, a gear case, a worm shaft rotatably accommodated in the gear case, and a worm wheel that is rotatably accommodated in the gear case and meshes with a worm provided on the worm shaft. A step of manufacturing the speed reducer provided, an annular clamping part, a power feeding connector part integrally formed with the clamping part, a plurality of power connection terminals provided in the connector part, and the plurality of power connections A step of manufacturing a connector unit having a plurality of connector-side connection terminals each having one end portion electrically connected to the terminal, and a flange portion provided at the opening end of the motor case and the gear case. and a step of assembling the said reduction gear and the motor main body while clamping fixing the clamping portion, and said speed reducer and the motor body In the step of applying seen, the worm shaft is connected to the armature shaft, in the step of clamping fixing the clamping portion between said flange portion gear case, on the outer side than the armature shaft in the radial direction of the armature shaft Among the end portions of the plurality of connector-side connection terminals, the other end portion disposed inside the sandwiching portion in the radial direction, and the plurality of brush- side connection terminals. It is electrically connected.

  According to the present invention, since the connector unit having the power feeding connector portion is formed separately from the brush holder, the specification of the brush holder remains unchanged with respect to the specification difference of the external connector. It is possible to respond by changing only the specifications. Thereby, the versatility of a brush holder is improved and the cost of this brushed electric motor can be reduced.

  In addition, according to the present invention, the motor body is configured as a single unit that can operate alone without the reduction gear or the connector unit being attached, so the motor body is a separate production line from the reduction gear or the connector unit. Can be manufactured. Therefore, even when a plurality of types of electric motors with reduction gears having different specifications of the connector are manufactured, the motor main body used for all of these specifications can be efficiently manufactured by one pole production.

  Furthermore, according to the present invention, since the motor body has a small and simple shape that does not have a connector portion, the transportation cost is reduced when the motor body is transported to an assembly base with a speed reducer or the like. be able to.

  Furthermore, according to the present invention, since the motor body can be operated alone, the reliability of the motor body can be checked by checking the operation after the motor body is produced and transported to each site. Can be increased.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a cross-sectional view of a power window motor according to an embodiment of the present invention. A power window motor 11 as an electric motor with a speed reducer is used as a drive source of a power window device provided in a vehicle (not shown). It is mounted inside the door of the vehicle body and drives the window glass to open and close via a regulator.

  The power window motor 11 includes a motor body 12 and a frame unit 13, which are assembled together to form one unit.

  2 is a perspective view showing details of the motor body shown in FIG. 1, FIG. 3 is a perspective view showing details of the brush unit shown in FIG. 1, and FIG. 4 is a positioning structure of the brush holder inside the motor yoke. FIG.

  As shown in FIGS. 1 and 2, the stator 14 of the motor body 12 includes a motor yoke 15 as a motor case. The motor yoke 15 is a bottomed cylindrical shape in which a steel plate, which is a conductor, is drawn by a press device or the like, so that the cross section is substantially oval and one end in the axial direction is open and the other end is closed by a bottom wall portion 15a. The opening end is provided with a flange portion 15b protruding in the radial direction. The oval motor yoke 15 is composed of a circular arc surface 15e and a flat surface 15f. On the inner surface of the circular arc surface 15e, as shown in FIG. 1, a pair of magnets 16 as field portions face each other with the same pole. The different poles that are fixed and located on the back surface of each magnet 16 reach the flat face 15f using the arc surface 15e and the flat face 15f of the motor yoke 15 as magnetic paths. A magnetic field is formed in the motor yoke 15 by the motor yoke 15 and these magnets 16. The flange portion 15b has three screw holes 15d.

  In the case shown in the drawing, a container-shaped motor yoke 15 formed by drawing a steel plate is used as the motor case. However, the present invention is not limited to this, and for example, a yoke body formed in a cylindrical shape by a steel plate. One end of the container may be closed with a lid member formed of resin or the like to form a container and used as a motor case.

  An armature 17 (armature) is accommodated in the motor yoke 15, and this armature 17 includes an armature shaft 18. The armature shaft 18 has a bearing support portion 15c of the bottom wall portion 15a of the motor yoke 15 at one end thereof. A radial direction is pivotally supported by a bearing 21 provided in the bearing, and a thrust direction is pivotally supported by a steel plate 21a disposed on the inner surface side of the bearing support portion 15c, a steel ball 21b disposed between the armature shaft 18 and the steel plate 21a. As a result, the armature shaft 18 is rotatably supported by the motor yoke 15.

  An amateur core 19 is fixed to the amateur shaft 18 so as to be positioned inside the magnetic field generated by the magnet 16. The amateur core 19 is formed in a columnar shape by laminating plate-shaped steel materials as conductors in the axial direction, and a plurality of slots 19a opened on the outer periphery thereof are provided side by side in the circumferential direction. A plurality of armature coils 22 are mounted on each slot 19a by overlapping winding, and these armature coils 22 rotate together with the armature core 19, that is, the armature shaft 18.

  A commutator (commutator) 23 is fixed to the amateur shaft 18 adjacent to the amateur core 19 in the axial direction. The commutator 23 includes a plurality of segment pieces (commutator pieces) 23a arranged in the circumferential direction, and the coil ends of the corresponding amateur coils 22 are electrically connected to the segment pieces 23a.

  A brush unit 24 is mounted inside the motor yoke 15 in order to supply a drive current to each armature coil 22 via the commutator 23. As shown in FIG. 3, the brush unit 24 includes a resin brush holder 25 and a pair of brushes 26 held by the brush holder 25.

The brush holder 25 is formed by injection molding of a resin material. As shown in FIG. 3, the brush holder 25 has an annular ring portion 25a formed in a substantially oval outer shape matching the shape of the inner surface opening of the motor yoke 15. And a plate-like base portion 25b formed integrally with the end portion of the ring portion 25a in the axial direction of the armature shaft 18 . The brush holder 25 is mounted inside the motor yoke 15 by being inserted into the motor yoke 15 from the ring portion 25a side so that the base portion 25b faces outward.

  A plurality of ribs 27 extending in the axial direction (a direction parallel to the armature shaft 18) and projecting at a predetermined height are provided on the outer periphery of the ring portion 25a, as shown in FIG. The holder 25 is attached to the motor yoke 15 so that these ribs 27 are in sliding contact with the arcuate surface 15e of the motor yoke 15 and the inner surface of the flat surface 15f. At this time, each rib 27 is slightly elastically deformed radially inward by contacting the inner surface of the motor yoke 15. As a result, the brush holder 25 is attached to the inner surface of the motor yoke 15 by light press fitting, and the brush holder 25 is prevented from being carelessly detached from the motor yoke 15. Further, as shown in FIG. 4, a stepped portion 28 is provided on the inner surface of the arc surface 15e of the motor yoke 15 with a contact surface 28a that is positioned at a predetermined depth from the opening end and perpendicular to the axial direction by drawing. In the brush holder 25, the end portion in the axial direction of the ring portion 25a contacts the stepped portion 28, that is, the contact surface 28a, so that the base portion 25b is substantially flush with the flange portion 15b at the opening end of the motor yoke 15. Thus, the motor yoke 15 is positioned in the axial direction.

  In the case shown in the figure, the brush holder 25 is abutted against the abutting surface 28a of the stepped portion 28 provided on the motor yoke 15, and is positioned inside the motor yoke 15. For example, by increasing the protruding amount of each rib 27 radially outward, the brush holder 25 is fitted into the motor yoke 15 by press fitting, and the brush holder 25 is moved into the motor yoke 15 by the press fitting. You may make it position.

  As shown in FIGS. 2 and 3, a through hole 31 is provided in the center of the base portion 25 b, and a bearing (metal bearing) 32 is attached to the through hole 31, and the other end side of the armature shaft 18. Is supported rotatably by the bearing 32. As described above, when the brush holder 25 is mounted on the motor yoke 15, one end of the armature shaft 18 is rotatably supported by the bottom wall portion 15 a of the motor yoke 15 and the other end side is freely rotatable by the brush holder 25. It has come to be supported. As a result, even if the frame unit 13 described later is not attached to the motor main body 12, the armature 17 can rotate inside the motor yoke 15, and the motor main body 12 is operated by supplying power to the pair of brushes 26. Can be made.

  As shown in FIG. 3, the pair of brushes 26 are arranged so as to be shifted from each other by 90 degrees in the rotation direction of the armature shaft 18, and are respectively held by the brush holder 25 in the ring portion 25a. When the brush holder 25 is attached to the motor yoke 15, as shown in FIG. 1, the commutator 23 is disposed inside the ring portion 25a of the brush holder 25, and the pair of brushes 26 are respectively connected to the commutator 23 (segment piece 23a). ) Is in sliding contact with the outer peripheral surface. Each brush 26 is movable forward and backward in a direction approaching and separating from the commutator 23, and is urged by a spring 33 attached to the ring portion 25 a and elastically slidably contacts the outer peripheral surface of the commutator 23. It is like that.

  FIG. 5 is a perspective view showing details of the frame unit 13 shown in FIG. 1, and FIG. 6 is a perspective view showing details of the connector unit 42 shown in FIG.

  As shown in FIG. 5, the frame unit 13 includes a speed reducer 41 and a connector unit 42. When the connector unit 42 is attached to the speed reducer 41, the frame unit 13 is configured as the frame unit 13.

  The speed reducer 41 has a gear case 43. The gear case 43 is formed into a predetermined shape by injection molding of a resin material, and a guide portion 43a and a guide portion 43b that serve as guides when the connector unit 42 is mounted are provided on the surface that closes the opening of the motor yoke 15. It has been. The gear case 43 is provided with three screw holes 43c opposite to the three screw holes 15d of the motor yoke 15. Reference numeral 43d denotes a nut hole for inserting a nut member (not shown) into the hole deep position of each screw hole 43c. Then, a fastening member (bolt or the like) 44 is inserted from each screw hole 15 d provided in the opening end of the motor yoke 15, that is, the flange portion 15 b, and a nut (not shown) in the nut hole 43 d is inserted through each screw hole 43 c of the gear case 43. And the opening of the motor yoke 15 is closed.

  As shown in FIG. 1, a reduction mechanism 45 is accommodated inside the gear case 43. The speed reduction mechanism 45 is a so-called worm gear mechanism, and includes a worm shaft 46 and a worm wheel 47.

  Both ends of the worm shaft 46 are axially supported by bearings 48 and 49 and are rotatably accommodated in the gear case 43, and a worm 46a is integrally formed on the outer periphery thereof. Further, a recess is formed in the end surface of the worm shaft 46 on the bearing 49 side, and a steel ball 49a is provided therein, and the thrust direction is axially supported by a thrust plate 49b disposed on the gear case 43 side. In order to connect the worm shaft 46 to the armature shaft 18, a connecting hole 46 b is provided at one end of the worm shaft 46 located on the opening side of the gear case 43, and a connecting projection 18 a is provided at the tip of the armature shaft 18. Yes. When the gear case 43 containing the speed reduction mechanism 45, that is, the frame unit 13 is attached to the motor yoke 15 of the motor body 12, the connecting projection 18 a provided at the tip of the armature shaft 18 is inserted into the connecting hole 46 b of the worm shaft 46. Thus, the worm shaft 46 is connected to the amateur shaft 18.

  The worm wheel 47 is fixed to the shaft center of the output shaft 51 and is rotatably accommodated in the gear case 43. The outer peripheral portion of the worm wheel 47 is engaged with the worm 46a. Thus, when the armature shaft 18 rotates, the rotation is decelerated to a predetermined rotational speed by the worm shaft 46, that is, the worm 46 a and the worm wheel 47, and is output from the output shaft 51.

  Although not shown in detail, the tip portion of the output shaft 51 protrudes from the gear case 43, and the tip portion that protrudes from the gear case 43 of the output shaft 51 is provided with a pinion (not shown). It is connected.

  On the other hand, the connector unit 42 is made of resin formed by injection molding of a resin material. As shown in FIG. 6, the connector unit 42 includes a sandwiching portion 52 and a power feeding connector portion 53 formed integrally therewith. Yes.

The clamping part 52 is formed in an annular shape having a substantially oval shape that matches the outer shape of the base part 25 b of the brush holder 25, and the clamping part 52 is located on the inner side of the clamping part 52 in the radial direction of the armature shaft 18. A flat plate portion 54 that is perpendicular to the axial direction of the armature shaft 18 is provided integrally with 52. The flat plate portion 54 is integrally provided with a pair of skirt portions 55 and 56 protruding in the axial direction toward the gear case 43, and the sandwiching portion 52 is guided by the guide portion 43a. The connector unit 42 is attached to the gear case 43 by inserting 55 and 56 into the opening of the gear case 43.

  A plurality of ribs 57 extending in the axial direction and projecting radially outward at a predetermined height are provided on the outer peripheries of the skirt portions 55 and 56, and the ribs 57 of the skirt portions 55 and 56 are connected to the gear case 43. It is inserted into the gear case 43 so as to be in contact with the inner surface and slightly elastically deform in the radial direction. As a result, the connector unit 42 is attached to the gear case 43 by light press-fitting and is not inadvertently detached from the gear case 43.

  A through hole 58 is provided in the axial center of the flat plate portion 54, and when the frame unit 13 is assembled to the motor body 12, the armature shaft 18 passes through the through hole 58 and is connected to the worm shaft 46.

  A sensor substrate 61 is mounted inside the one skirt portion 55 of the connector unit 42 while being separated from the flat plate portion 54 by a predetermined distance and parallel to the flat plate portion 54. A pair of hall sensors 62 are mounted on the sensor substrate 61 as rotation sensors, and these hall sensors 62 are arranged so as to face the ring magnet 63 fixed to the armature shaft 18 in the axial direction. The ring magnet 63 has a plurality of magnetic poles arranged at equal intervals in the circumferential direction. As a result, when the armature shaft 18 rotates, a pulse signal having a cycle inversely proportional to the rotational speed of the armature shaft 18 is output from each Hall sensor 62. It has come to be. In addition, the Hall sensors 62 are arranged so that their phases are shifted from each other by 90 degrees in the rotation direction, so that the rotation direction of the amateur shaft 18 can be detected based on the generation order of the pulse signals output from the Hall sensors 62. It can be done.

  Each Hall sensor 62 is connected to an external connector (not shown) via a sensor terminal (not shown) disposed in the connector portion 53 by a lead plate (not shown) embedded in the connector unit 42 by insert molding. The pulse signal output from 62 is input to a motor control device (not shown) via an external connector. The control device controls the operation of the motor body 12 based on the rotational speed and direction of the amateur shaft 18 recognized from the input pulse signal.

  When the frame unit 13 is attached to the motor body 12, the flat plate portion 54 of the frame unit 13 is disposed so as to overlap the base portion 25 b of the brush holder 25 in the axial direction. As a result, the brush holder 25 is sandwiched and fixed between the flat plate portion 54 and the step portion 28 of the motor yoke 15.

  Here, as shown in FIG. 2, the base portion 25b of the brush holder 25 is provided with three engagement holes 64 that open toward the gear case 43. As shown in FIG. The portion 54 is integrally provided with three engaging protrusions 65 protruding toward the motor body 12 side. Then, the engaging protrusions 65 provided on the connector unit 42 are engaged with the corresponding engaging holes 64 provided on the brush holder 25, whereby the sandwiching portion 52 is positioned with respect to the brush holder 25. .

  An annular seal member 66 is attached to the holding portion 52 so as to cover it. The material of the seal member 66 is, for example, an elastomer material such as synthetic rubber, and is formed integrally with the sandwiching portion 52 by two-color molding. When the frame unit 13 is assembled to the motor body 12, the seal member 66 is sandwiched between the flange portion 15b of the motor yoke 15 and the sandwiching portion 53 and between the gear case 43 and the sandwiching portion 53. It has become. That is, the sandwiching portion 52 is also sandwiched and fixed (fixed by being sandwiched) between the flange portion 15 b of the motor yoke 15 and the gear case 43 via the seal member 66. As a result, the sealing member 66 is in contact with the flange portion 15 b of the motor yoke 15 and the opening end of the gear case 43 even when the connector unit 42 is fixed by sandwiching the clamping portion 52 between the motor yoke 15 and the gear case 43. Thus, it is possible to prevent foreign matter such as rainwater and dust from entering the sandwiched portion.

  In the illustrated case, the seal member 66 is formed integrally with the sandwiching portion 52 by two-color molding. However, the present invention is not limited to this, and the seal member 66 formed separately from the sandwiching portion 52 is provided. You may make it attach to the clamping part 52 so that it may be located between the flange part 15b and the clamping part 53 of the motor yoke 15, and between the gear case 43 and the clamping part 53. FIG.

  On the other hand, as shown in FIGS. 1 and 6, the connector portion 53 is formed in a box shape having a rectangular cross section with one end opened, and via a connecting portion 67 protruding from between the motor yoke 15 and the gear case 43. It is formed integrally with the clamping part 52. Further, the connector portion 53 is disposed outside the gear case 43 and the motor yoke 15 so as to be adjacent to the gear case 43, and is connected to an external connector (not shown) provided on the vehicle side. When the connector unit 42 is attached to the gear case 43, the connecting portion 67 is supported by the guide portion 43b and positioned.

  In the connector unit 42, for example, a pair of lead plates formed of a conductive plate material such as a copper plate is embedded by insert molding, and by projecting one end of these lead plates into the connector portion 53, A pair of power connection terminals 71 are provided inside the connector portion 53. When an external connector is connected to the connector portion 53, each power connection terminal 71 is connected to the control device via the external connector.

  The other end of the pair of lead plates embedded in the connector unit 42 protrudes in the axial direction on the side where the motor yoke 15 is attached from the flat plate portion 54 inside the pinching portion 52, and as shown in FIG. In addition, a pair of connector-side connection terminals 72 are provided inside the sandwiching portion 52. These connector-side connection terminals 72 protrude in the axial direction from the flat plate portion 54 toward the brush holder 25 and are arranged side by side.

  In the case shown in the figure, the connector side connection terminal 72 is formed by a lead plate together with the power supply connection terminal 71 and is electrically connected to the power supply connection terminal 71. The terminal 72 and the power connection terminal 71 may be formed separately and electrically connected by a lead plate.

  On the other hand, as shown in FIG. 2, the brush holder 25 is provided with a pair of brush side connection terminals 73 facing the connector side connection terminals 72 of the connector unit 42.

  These brush side connection terminals 73 are formed of a conductive plate material such as a copper plate, for example, and each have a connection hole 73a having a rectangular cross section. These connection holes 73a are formed in a size corresponding to the connector-side connection terminals 72, and each brush-side connection terminal 73 is formed on the brush holder 25 so that these connection holes 73a open toward the gear case 43. It is fixed side by side on the base portion 25b. Further, as shown in FIG. 3, the brush-side connection terminal 73 is provided with a plate-like connection portion 73b, and these connection portions 73b are electrically connected to the corresponding brushes 26 through lead plates 74 and 75, respectively. It is connected to the.

  A circuit breaker 76 is connected between one lead plate 74 and the brush 26 in order to protect the armature coil 22 from overcurrent.

  FIG. 7 is a cross-sectional view showing details of a connection portion between the brush side connection terminal 73 and the connector side connection terminal 72. When the clamping portion 52 is disposed so as to overlap the brush holder 25 in the axial direction, the connector side connection terminal 72 is shown. Is inserted through the connection hole 73 a of the corresponding brush side connection terminal 73 and is electrically connected to the brush side connection terminal 73. Accordingly, the drive current supplied from the control device via the external connector can be supplied to each brush 26 via the power supply connection terminal 71, the connector side connection terminal 72, and the brush side connection terminal 73 of the connector portion 53. .

  FIG. 8 is a process diagram showing a manufacturing process of the power window motor 11 shown in FIG. 1, and FIGS. 9A and 9B are diagrams showing an assembly process of the motor body, respectively. FIGS. 11A and 11B are diagrams showing an assembly process of the motor main body 12 and the frame unit 13, respectively.

  Next, based on FIGS. 8-11, the manufacturing method of the power window motor 11 of this invention is demonstrated.

  As shown in FIG. 8, in the method for manufacturing the power window motor 11, the motor body 12 and the frame unit 13 are on separate production lines, that is, the manufacturing process of the motor body 12 and the manufacturing process of the frame unit 13 are performed in parallel. Manufactured by advanced parallel method.

  As shown in FIG. 9A, in the manufacturing process of the motor body 12, first, in the stator assembly process, a pair of magnets 16 are mounted on the inner surface of the motor yoke 15 and the bottom wall portion 15 a of the motor yoke 15. The stator 14 is assembled by holding the bearing 21 on the bearing support portion 15c provided on the stator. Next, in the amateur assembly process, the commutator 23 and the amateur core 19 are fixed to the amateur shaft 18, the armature coil 22 is wound around the armature core 19, and the coil end is connected to the commutator 23 to assemble the armature 17. It is done. Next, in the brush unit assembly process, the pair of brushes 26, the spring 33, the brush side connection terminal 73, and the like are attached to the resin-molded brush holder 25, and the brush unit 24 is assembled. When the ring magnet 63 is prepared in addition to the stator 14, the armature 17, and the brush unit 24, the armature 17 and the brush unit 24 are assembled to the stator 14 and the arm shaft 18 is then ringed in the motor body assembly process. The magnet 63 is fixed, and the motor body 12 is completed as shown in FIG. The bearing 21 can be configured to be fixed to the end of the armature shaft 18 in advance.

  On the other hand, as shown in FIG. 10A, in the manufacturing process of the frame unit 13, first, the gear case 43 is assembled in the gear case assembling process. Next, in the speed reduction mechanism assembling step, the speed reduction mechanism 45 including the worm shaft 46 and the worm wheel 47 and the output shaft 51 are assembled to the gear case 43 to assemble the speed reducer 41. Thus, the speed reducer 41 is manufactured by the gear case assembly process and the speed reduction mechanism assembly process. Next, in the connector unit manufacturing process, the lead plate is insert-molded with a resin material to form the connector portion 53 having the power connection terminal 71, the flat plate portion 54 having the connector side connection terminal 72, and the sandwiching portion 52. Then, the sensor unit 61 is assembled to this to assemble the connector unit 42. When the speed reducer 41 and the connector unit 42 are prepared, the connector unit 42 is then attached to the speed reducer 41 in the frame unit assembling step. As shown in FIG. Complete.

  As shown in FIG. 11A, when the motor body 12 manufactured by the motor body assembly process and the frame unit 13 manufactured by the frame unit assembly process are prepared, then in the power window motor assembly process, The gear case 43 of the speed reducer 41 is fixed to the flange portion 15b of the motor body 12 so that the pinching portion 52 of the connector unit 42 is pinched (pinched) between the motor yoke 15 and the gear case 43. At this time, the brush holder 25 lightly press-fitted into the inner surface of the motor yoke 15 is also sandwiched and fixed between the step portion 28 and the flat plate portion 54 of the motor yoke 15.

  Then, the connecting projection 46 a provided on the armature shaft 18 is inserted into the connecting hole 46 b provided on the worm shaft 46, and the worm shaft 46 is connected to the armature shaft 18. Further, the connector side connection terminal 72 provided in the connector unit 42 is electrically connected to the brush side connection terminal 73 provided in the brush holder 25, and each brush 26 is connected to the power connector 71 of the connector portion 53 connected to the external connector. Is electrically connected.

  As a result, the frame unit 13 is assembled to the motor body 12, and the power window motor 11 is completed.

  FIG. 12 is a diagram for explaining a method of manufacturing two types of power window motors having different connector specifications.

  In the power window motor 11, a connector unit 42 having a power feeding connector portion 53 is formed separately from the brush holder 25, and the connector unit 42 is sandwiched and fixed between the speed reducer 41 and the motor body 12. Thus, it is possible to easily cope with the difference in specifications of the external connector by changing only the specifications of the connector unit 42 while keeping the specifications of the brush holder 25 as they are.

  For example, as shown in FIG. 12, when manufacturing the power window motor 11 having two specifications with different connector 53 insertion directions, the speed reducer 41 and the motor body 12, that is, the brush holder 25 have the same specifications. By using two types of connector units 42 with different specifications of the connector portion 53, the power window motor 11 having two specifications can be easily manufactured.

  As described above, in the power window motor 11, the connector unit 42 including the power feeding connector portion 53 is formed separately from the brush holder 25. Therefore, the specifications of the connector portion 53 can be matched to the external connector. When manufacturing a plurality of different types of power window motors 11, the brush holder 25 having a common specification can be used. Therefore, the versatility of the brush holder 25 with respect to the difference in specifications of the external connector can be enhanced, and the cost of the power window motor 11 can be reduced.

  Further, in the power window motor 11, the holding part 52 of the connector unit 42 is disposed so as to overlap the base part 25 b of the brush holder 25 in the axial direction, whereby the brush side connection terminal 73 and the connector unit 42 provided on the brush holder 25 are arranged. Since the connector 26 is electrically connected to the connector side connection terminal 72 and the brushes 26 are connected to the power supply connection terminals 71 provided in the connector portion 53, the connector unit 42 and the brush holder 25 are separated from each other. Even with this configuration, each brush 26 and the power connection terminal 71 can be electrically connected with a simple configuration.

  On the other hand, in the power window motor 11, the armature shaft 18 of the motor body 12 is divided from the worm shaft 46 so as to be connected to the worm shaft 46 of the speed reducer 41, and when the motor body 12 is completed, Since the yoke 15 and the brush holder 25 are rotatably supported, the armature shaft 18, that is, the armature 17 can be rotated even if the frame unit 13 is not attached to the motor body 12. The brush holder 25 is provided with a pair of brush-side connection terminals 73 that are electrically connected to the brush 26 so as to be exposed from the brush holder 25 to the outside. Therefore, the motor main body 12 can be operated alone by directly connecting a power source to these brush side connection terminals 73.

  Thus, in this power window motor 11, the motor body 12 is configured as a single unit that can be operated alone without the reduction gear 41 or the connector unit 42 being attached, as shown in FIG. The motor body 12 can be manufactured on a manufacturing line different from the frame unit 13. Therefore, even when a plurality of types of power window motors 11 having different specifications of the connector portion 53 are manufactured, the motor body 12 used for all of these specifications can be efficiently manufactured by one-pole production.

  Further, in this power window motor 11, the motor main body 12 has a small and simple shape without the connector portion 53, so that the transportation cost for transporting the motor main body 12 to the assembly base with the frame unit 13 is reduced. Can be reduced.

  Furthermore, in this power window motor 11, since the motor main body 12 can be operated alone, it is possible to inspect the operation of the motor main body 12 after production of the motor main body 12 and before transportation to each base. Thereby, the motor main body 12 with high operation reliability can be transported to each base.

  Next, another embodiment of the present invention will be described in detail with reference to the drawings. In addition, about the part which has the function similar to embodiment mentioned above, the same code | symbol is attached | subjected and the detailed description is abbreviate | omitted. FIG. 13 is a perspective view of a brush unit according to another embodiment viewed from the back side.

  In the brush unit 80 according to another embodiment, a pair of brushes 26 are arranged opposite to each other on the base portion 25b of the brush holder 25 constituting the brush unit 80 as compared with the above-described embodiments, that is, the armature shafts are mutually attached. 18 (see FIG. 1) is different in that it is arranged to be shifted by 180 degrees along the rotation direction.

  Each brush 26 is provided on both arc sides (upper and lower sides in the drawing) having a relatively large space in the substantially oval base portion 25b, and accordingly, in the vicinity of each brush 26 in the base portion 25b. Are provided with springs 33 for urging each brush 26 toward the commutator 23 (see FIG. 1). Further, the connection portion 73b of the brush side connection terminal 73 that is electrically connected to each brush 26 is electrically connected via the lead plates 74 and 75, the choke coil 81, the capacitor 82, the circuit breaker 76, and the like. Yes. Further, each lead plate 74, 75 is inserted into each insert portion 83 integrally provided in the base portion 25b so as to face the center of the through hole 31 formed in the axis of the base portion 25b by insert molding or the like. Has been. Each electrical connection portion is connected by spot welding or the like.

  As described above, in this embodiment, each connection portion 73b is provided at a position farther from each connection portion 73b according to the above-described embodiment. Therefore, although not shown in detail, a pair of connector-side connection terminals 72 (see FIG. 5) that are insert-molded in the connector unit 42 are provided so as to correspond to the intervals between the connection portions 73b. The choke coil 81 and the capacitor 82 serve to absorb electrical noise radiated to the outside through the brushes 26.

  Also in the power window motor 11 having the brush unit 80 configured as described above, the same operational effects as those of the above-described embodiment can be obtained. In addition, according to other embodiments, the brushes 26 are provided to be opposed to and separated from each other, so that the lead plates 74 and 75 and the connection portions 73b that are electrically connected to the brushes 26 are also provided. The electronic components can be arranged separately from each other in the brush holder 25, and therefore, these electronic components can be easily assembled to the brush holder 25.

  It goes without saying that the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the invention. For example, in the above-described embodiment, the present invention is applied to the power window motor 11 used as a drive source of the power window device. However, the present invention is not limited thereto. For example, the slide door, the back door, You may make it apply this invention to the electric motor with a reduction gear used for other uses, such as the drive source of the automatic opening / closing apparatus for vehicles which drives opening / closing bodies, such as a sunroof automatically.

  Moreover, in the said embodiment, although the brush side connection terminal 73 is formed in a concave shape, and the connector side connection terminal 72 is formed in a convex shape, it is not restricted to this, The brush side connection terminal 73 is a convex shape. The connector side connection terminal 72 may be formed in a concave shape.

  Further, in the above embodiment, the axial end of the ring portion 25a of the brush holder 25 is brought into contact with the contact surface 28a of the step portion 28 provided on the inner surface of the motor yoke 15, so that the interior of the motor yoke 15 is reached. When the clamping portion 52 of the connector unit 42 is clamped between the motor yoke 15 and the gear case 43, the brush holder 25 also has a stepped portion 28 of the motor yoke 15 and a flat plate portion 54 of the connector unit 42. However, the present invention is not limited to this, and is not limited to this, and is positioned at a position facing the stepped portion 28 on the axial end surface of the ring portion 25a, or at a position facing the connector unit 42 described later on the base portion 25b. A deformable small protrusion is provided, and the protrusion of the ring portion 25a contacts the step portion 28 when lightly press-fitted in the motor yoke 15 in the axial direction. The brush holder 25 is sandwiched between the stepped portion 28 of the motor yoke 15 and the flat plate portion 54 of the connector unit 42 by deforming these small protrusions by fixing the motor yoke 15 and the gear case 43. You may make it do.

  Further, in the embodiment, the brush holder 25 holds the pair of brushes 26, the connector unit 42 is provided with the pair of connector side connection terminals 72, and the brush holder 25 faces the pair of connector side connection terminals 72. However, the present invention is not limited to this, and the brush unit 24 includes a common brush, a low-speed operation brush, and a high-speed operation, such as a wiper motor used as a drive source of the wiper device. Three brushes 26 for driving brushes may be provided. In this case, the brush holder 25 is provided with three brushes 26, the connector unit 42 is provided with three connector-side connection terminals 72, and the brush holder 25 has three brush-side connections facing the three connector-side connection terminals 72. The terminal 73 can also be provided.

It is a cross-sectional view of the power window motor which is one embodiment of the present invention. It is a perspective view which shows the detail of the motor main body shown in FIG. It is a perspective view which shows the detail of the brush unit shown in FIG. It is sectional drawing which shows the positioning structure to the inside of the motor yoke of a brush holder. It is a perspective view which shows the detail of the frame unit shown in FIG. FIG. 6 is a perspective view showing details of the connector unit shown in FIG. 5. It is sectional drawing which shows the detail of the connection part of a brush side connection terminal and a connector side connection terminal. It is process drawing which shows the manufacturing process of the power window motor shown in FIG. (A), (b) is a figure which shows the assembly process of a motor main body, respectively. (A), (b) is a figure which shows the assembly process of a frame unit, respectively. (A), (b) is a figure which shows the assembly | attachment process of a motor main body and a frame unit, respectively. It is a figure explaining the manufacturing method of two types of power window motors from which the specification of a connector part differs. It is the perspective view which looked at the brush unit which concerns on other embodiment from the back side.

Explanation of symbols

11 Power window motor (electric motor with reduction gear)
12 Motor body 13 Frame unit 14 Stator 15 Motor yoke (motor case)
15a Bottom wall portion 15b Flange portion 15c Bearing support portion 15d Screw hole 15e Arc surface 15f Flat surface 16 Magnet (field portion)
17 amateur 18 amateur shaft 18a connecting convex part 19 amateur core 19a slot 21 bearing 21a steel plate 21b steel ball 22 amateur coil 23 commutator 23a segment piece 24 brush unit 25 brush holder 25a ring part 25b base part 26 brush 27 rib 28 step part 28a Contact surface 31 Through hole 32 Bearing 33 Spring 41 Reduction gear 42 Connector unit 43 Gear case 43a Guide portion 43b Guide portion 43c Screw hole 43d Nut hole 44 Fastening member 45 Deceleration mechanism 46 Worm shaft 46a Worm 46b Connecting hole 47 Warm wheel 48, 49 Bearing 49a Steel ball 49b Thrust plate 51 Output shaft 52 Nipping part 53 Connector part 54 Flat plate part 55, 56 Skirt part 57 58 Through-hole 61 Sensor board 62 Hall sensor 63 Ring magnet 64 Engagement hole 65 Engagement protrusion 66 Seal member 67 Connection part 71 Power supply connection terminal 72 Connector side connection terminal 73 Brush side connection terminal 73a Connection hole 73b Connection part 74,75 Lead plate 76 Circuit breaker 80 Brush unit 81 Choke coil 82 Capacitor 83 Insert part

Claims (4)

A motor case which is formed in a bottomed cylindrical shape with one end opened and a field portion is provided on the inner surface;
A brush holder mounted inside the motor case and holding a plurality of brushes;
One end of which is rotatably supported by the motor case and the other end of which is rotatably supported by the brush holder;
A plate-like base portion formed integrally with the end of the brush holder in the axial direction of the armature shaft;
A through hole provided in the base portion and into which the armature shaft is inserted;
A commutator fixed to the amateur shaft and in sliding contact with the plurality of brushes;
A plurality of armature coils each connected to the commutator and rotating with the armature shaft;
A gear case attached to the opening end of the motor case and closing the opening of the motor case;
A worm shaft that is rotatably accommodated in the gear case and connected to the armature shaft when the gear case is attached to the motor case;
A worm wheel that is rotatably accommodated in the gear case and meshes with a worm provided on the worm shaft;
Said that for the brush holder is disposed to overlap in the axial direction is sandwiched and fixed with the said motor case gear case, and clamping of the annular provided outside than its armature shaft in the radial direction of the armature shaft, A connector unit including a power feeding connector portion formed integrally with the sandwiching portion and disposed outside the motor case;
A plurality of power connection terminals provided in the connector portion;
A plurality of brush-side connection terminals provided on the brush holder and electrically connected to the corresponding brushes;
Corresponding to a case where one end portion is provided in the connector unit and electrically connected to the plurality of power supply connection terminals, and the clamping portion is disposed so as to overlap the base portion in the axial direction. the other end into a plurality of brush-side connection terminals have a plurality of connector-side connection terminals electrically connected respectively,
The clamping portion is clamped and fixed between a flange portion provided at an opening end of the motor case and the gear case, and the other end portions of the plurality of connector side connection terminals are connected to the clamping portion in the radial direction of the armature shaft. An electric motor with a reduction gear, characterized in that the electric motor is arranged on the inner side . 2. The electric motor with a reduction gear according to claim 1 , wherein the brush holder is positioned inside the motor case by bringing the axial end of the brush holder into contact with a step provided on an inner surface of the motor case. An electric motor with a reduction gear , wherein the brush holder is sandwiched between the connector unit and the motor case . The electric motor with reduction gear according to claim 1 Symbol mounting, the side of the brush holder is press-fitted to the inner surface of the motor case positioned inside of the motor case, the motor case of the sandwiching portion through the brush holder reduction gear with electric motor, wherein Rukoto is supported. A motor case that is formed in a container shape with one end open and the field portion is fixed to the inner surface, a brush holder that is mounted inside the motor case and holds a plurality of brushes, and provided in the brush holder, and A plurality of brush-side connection terminals electrically connected to the corresponding brush; an armature shaft having one end rotatably supported by the motor case and the other end rotatably supported by the brush holder; and the armature shaft A base portion formed at the end of the brush holder in the axial direction, a through hole provided in the base portion and into which the armature shaft is inserted, and a commutator fixed to the armature shaft and in sliding contact with the brush And a plurality of armature coils each connected to the commutator and rotating together with the armature shaft. And a step,
Manufacturing a reduction gear comprising a gear case, a worm shaft rotatably accommodated in the gear case, and a worm wheel that is rotatably accommodated in the gear case and meshes with a worm provided on the worm shaft;
An annular holding portion, a power supply connector portion formed integrally with the holding portion, a plurality of power connection terminals provided on the connector portion, and one end portion of each of the plurality of power connection terminals is electrically connected A step of manufacturing a connector unit having a plurality of connector side connection terminals connected to
A step of clamping and fixing the clamping portion between a flange portion provided at an opening end of the motor case and the gear case, and assembling the motor body and the speed reducer,
In the step of assembling the motor body and the speed reducer, the worm shaft is connected to the amateur shaft,
In the step of clamping and fixing the clamping part between the flange part and the gear case, the clamping part is disposed outside the armature shaft in the radial direction of the armature shaft, and the plurality of connector side connection terminals electric motor with a and the other end disposed inside than the holding portions in the radial direction of the end portion, a reduction gear the plurality of brush-side connection terminals and said Rukoto is electrically connected Manufacturing method .

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