DC brushless motor for electrical power steering and the production method thereof
First Claim
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1. A DC brushless motor for electrical power steering, driven by polyphase alternating current power, for outputting steering torque, said DC brushless motor for electrical power steering comprising:
- a frame;
a stator secured on said frame; and
a rotor arranged opposite to said stator through an air gap;
said stator comprising;
a stator core; and
a polyphase stator coil built in said stator core;
said stator core, formed by connecting a plurality of split core pieces, comprising;
an annular back core; and
a plurality of tee cores projected radially from said back core;
a slot being formed on said tee core adjacent to said stator core, and said stator coil being incorporated in said slot, said rotor comprising;
a rotor core; and
a plurality of magnets fixed onto the surface of the outer periphery of the rotor core;
said stator core and stator coil being molded by a molding agent, with the stator coil incorporated in the stator core.
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Accused Products
Abstract
The stator core of a motor comprises an annular back core, and a plurality of tees created separately from the back core and secured onto the inner periphery of the back core. A stator coil is wound on each of the tees by a distributed or concentrated winding method. The stator core and stator coil are formed by molding.
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Citations
30 Claims
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1. A DC brushless motor for electrical power steering, driven by polyphase alternating current power, for outputting steering torque, said DC brushless motor for electrical power steering comprising:
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a frame;
a stator secured on said frame; and
a rotor arranged opposite to said stator through an air gap;
said stator comprising;
a stator core; and
a polyphase stator coil built in said stator core;
said stator core, formed by connecting a plurality of split core pieces, comprising;
an annular back core; and
a plurality of tee cores projected radially from said back core;
a slot being formed on said tee core adjacent to said stator core, and said stator coil being incorporated in said slot, said rotor comprising;
a rotor core; and
a plurality of magnets fixed onto the surface of the outer periphery of the rotor core;
said stator core and stator coil being molded by a molding agent, with the stator coil incorporated in the stator core. - View Dependent Claims (2, 3)
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4. A DC brushless motor for electrical power steering, driven by polyphase alternating current power, for outputting steering torque, said DC brushless motor for electrical power steering comprising:
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a frame;
a stator secured on said frame; and
a rotor arranged opposite to said stator through an air gap;
said stator comprising;
a stator core; and
a polyphase stator coil built in said stator core;
said stator core, formed by connecting a plurality of split core pieces, comprising;
an annular back core; and
a plurality of tee cores projected radially from said back core;
a slot being formed on said tee core adjacent to said stator core, and said stator coil being incorporated in said slot, said rotor comprising;
a rotor core; and
a plurality of magnets fixed onto the surface of the outer periphery of the rotor core;
said stator core and stator coil being molded by a molding agent, with the stator coil incorporated into the stator core, and the surface opposite to the rotor as an integral mold obtained by said molding process, being provided with machining.
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5. A DC brushless motor for electrical power steering, driven by polyphase alternating current power, for outputting steering torque, said DC brushless motor for electrical power steering comprising:
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a frame;
a stator secured on said frame; and
a rotor arranged opposite to said stator through an air gap;
said stator comprising;
a stator core; and
a polyphase stator coil built in said stator core;
said stator core, formed by connecting a plurality of split core pieces, comprising;
an annular back core; and
a plurality of tee cores projected radially from said back core;
said stator core being press-fit into said frame;
a slot being formed on said tee core adjacent to said stator core, and said stator coil being incorporated in said slot, said rotor comprising;
a rotor core; and
a plurality of magnets fixed onto the surface of the outer periphery of the rotor core;
said stator core and stator coil being molded by a molding agent, while the stator coil incorporated in the stator core is fixed on the frame. - View Dependent Claims (6, 7)
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8. A DC brushless motor for electrical power steering, driven by polyphase alternating current power, for outputting steering torque, said DC brushless motor for electrical power steering comprising:
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a frame;
a stator secured on said frame; and
a rotor arranged opposite to said stator through an air gap;
said stator comprising;
a stator core; and
a polyphase stator coil built in said stator core;
said stator core, formed by connecting a plurality of split core pieces, comprising;
an annular back core; and
a plurality of tee cores projected radially from said back core;
a slot being formed on said tee core adjacent to said stator core, and said stator coil being composed of a wire rod whose diameter is smaller than the circumferential space between the closest sections, out of the circumferential spaces between said adjacent tee cores, and said stator coil being incorporated in said slot, said rotor comprising;
a rotor core; and
a plurality of magnets fixed onto the surface of the outer periphery of the rotor core;
said stator core and stator coil being molded by a molding agent, with the stator coil incorporated in the stator core.
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9. A DC brushless motor for electrical power steering, controlled by a power conversion apparatus for converting the electric power supplied from a 14-volt or 42-volt on-board power source, into polyphase alternating current power, for outputting steering torque, said DC brushless motor for electrical power steering comprising:
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a frame;
a stator secured on said frame; and
a rotor arranged opposite to said stator through an air gap;
said stator comprising;
a stator core; and
a polyphase stator coil built in said stator core;
said stator core, formed by connecting a plurality of split core pieces, comprising;
an annular back core; and
a plurality of tee cores projected radially from said back core;
a slot being formed on said tee core adjacent to said stator core, and said stator coil composed of a plurality of unit coils and incorporated in said slot, said unit coils, composed of a wire rod whose diameter is smaller than the circumferential space between the closest sections, out of the circumferential spaces between tee cores, and continuously wound on the tee core;
said rotor comprising;
a rotor core; and
a plurality of magnets fixed onto the surface of the outer periphery of the rotor core;
said stator core and stator coil being molded by a molding agent, while the stator coil incorporated in the stator core is fixed on the frame;
a 8-pole 9-slot, 10-pole 9-slot or 10-pole 12-slot relationship holding between the number of said magnets (in the plural) and the number of said slots. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A DC brushless motor for electrical power steering for outputting the steering torque, controlled by a power conversion apparatus for converting the power obtained from an on-board power source, into polyphase a.c. power and for outputting the power, said DC brushless motor for electrical power steering comprising:
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a frame;
a stator secured on said frame;
a rotor arranged opposite to said stator through an air gap;
a flange for blocking both ends of the frame in the axial direction; and
a sensor for checking the magnetic pole position of the rotor said stator comprising;
a stator core; and
a polyphase stator coil built in said stator core;
said stator core, formed by connecting a plurality of split core pieces, comprising;
an annular back core; and
a plurality of tee cores projected radially from said back core;
wherein a slot is formed on said tee core adjacent to said stator core, and said stator coil is composed of a plurality of unit coils, and is incorporated in said slot;
said rotor comprising;
a shaft;
a rotor core provided on the shaft; and
a plurality of magnets fixed onto the surface of the outer periphery of the rotor core;
said DC brushless motor for electrical power steering further characterized in that said stator core and stator coil are molded by a molding agent, with the stator coil incorporated in the stator core, said shaft being rotatably supported by a bearing, said bearing being arranged on the flange, one side of said flange being provided with a recess, said recess, as a cylindrical member concentric with the shaft, being located inward of the axial end of the frame and extending to the position opposed to the coil end, and one side of said bearing being arranged on the position of the recess radially opposite to the coil end. - View Dependent Claims (21, 22, 23, 24, 25, 26)
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27. A DC brushless motor for electrical power steering manufacturing method, driven by polyphase alternating current power, for outputting steering torque, said manufacturing method comprising:
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a first step of assembling a stator coil into a stator core;
a subsequent second step of press-fitting into the frame a plurality of positions of the stator core incorporating the stator coil in the circumferential direction, and obtaining a structure composed of the stator core incorporating the stator coil, secured to the frame;
a subsequent third step of mounting a jig on said structure in such a way that the jig and frame will enclose the stator core and the coil end of the stator coil protruding axially from the axial end of the stator core;
a subsequent fourth step of injecting the molding agent into the space enclosed by the jig and frame, thereby filling the molding agent into the air gap between the coil end and stator core, the air gap of the stator coil, the air gap between stator core and stator coil, and the air gap between the stator core and frame;
a subsequent fifth step of solidifying the molding agent; and
a subsequent sixth step of removing the jig. - View Dependent Claims (28, 29, 30)
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Specification