Electric motor and electric power steering apparatus employing the electric motor

• US 6,140,728 A
• Filed: 08/10/1999
• Issued: 10/31/2000
• Est. Priority Date: 08/21/1998
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Mizutani, Ryoji, Tomita, Masaaki
• Primary Examiner(s): MULLINS, BURTON S
• Application Number:
  US09/370,987
• Time in Patent Office: 448 Days
• Field of Search: 310/156, 310/254, 310/259, 310/43, 310/218
• US Class Current: 310/216.079
• CPC Class Codes: B62D 5/0403 characterised by constructional features, e.g. common housing for motor and gear box
• CPC Class Codes: H02K 1/278 Surface mounted magnets; Inset magnets
• CPC Class Codes: H02K 15/0025 Shaping or compacting conductors or winding heads after the installation of the winding in the core or machine methods or apparatus for simultaneously twisting a plurality of hairpins prior to mounting H02K15/0428; Applying fastening means on winding heads
• CPC Class Codes: H02K 15/095 by laying conductors around salient poles
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 2203/12 Machines characterised by the bobbins for supporting the windings
• CPC Class Codes: H02K 3/325 for windings on salient poles, such as claw-shaped poles
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: H02K 5/148 Slidably supported brushes
• CPC Class Codes: H02K 7/06 Means for converting reciprocating motion into rotary motion or vice versa

Abstract

An electric motor has a rotor for rotation in a stator and a plurality of permanent magnets arranged on an outer peripheral surface of the rotor. A radially inner side surface of each permanent magnet is a curved to generally be convex in a radially inward direction. The outer peripheral surface of the rotor has curved recess surfaces, each of which contacts the radially inner side curved surface of a corresponding permanent magnet so that magnetic flux between adjacent permanent magnets is considerably prevented from locally concentrating within the rotor.

Claims

1. An electric motor comprising:

a stator, the stator having a plurality of tooth parts, each tooth part having a radially inner side end and a radially outer side end, the radially inner side end of each tooth part having a magnetic pole portion extending in a circumferential direction and a protruded portion protruding in the circumferential direction from the radially outer side end, the magnetic pole portion and protruded portion defining a coil mounting portion wrapped by an insulating sheet;

a coil provided around each tooth part;

a yoke having a plurality of dovetail grooves extending along a radially inner peripheral surface of the yoke, the yoke containing the tooth parts and coil, the tooth parts, coil and yoke being integrated by molding using a resin having at least one of adhesion and electric insulation characteristics;

a rotor that rotates within the stator, the rotor having an outer peripheral surface; and

a plurality of permanent magnets disposed on the outer peripheral surface of the rotor, each magnet having a radially inner side surface, a radially outer side surface and a pair of opposite ends, the radially inner side surface of each magnet being curved to generally be convex in a radially inward direction and the outer peripheral surface of the rotor having a plurality of curved recess surfaces, each of the curved recess surfaces contacting the radially inner side curved surface of a corresponding magnet.

2. The electric motor according to claim 1, wherein the insulating sheet comprises an electrically insulating material having a thickness substantially equal to an amount of protrusion the protruded portion protrudes from the radially outer side end of each tooth part.

3. The electric motor according to claim 1, wherein the coil mounting portion includes a longitudinally extending groove to allow passage of the resin having electric insulation characteristics.

4. The electric motor according to claim 1, wherein each tooth part is mounted to the yoke portion by fitting the protruded portion into a corresponding dovetail groove.

5. An electric motor comprising:

a stator, the stator having a plurality of tooth parts, each tooth part having a radially inner side end and a radially outer side end;

a coil provided around each tooth part, the coil being formed into a predetermined shape by being pressed using a press-forming jig;

a yoke having a plurality of dovetail grooves extending along a radially inner peripheral surface of the yoke, the yoke containing the tooth parts and coil, the tooth parts, coil and yoke being integrated by molding using a resin having at least one of adhesion and electric insulation characteristics;

a rotor that rotates within the stator, the rotor having an outer peripheral surface; and

a plurality of permanent magnets disposed on the outer peripheral surface of the rotor, each magnet having a radially inner side surface, a radially outer side surface and a pair of opposite ends, the radially inner side surface of each magnet being curved to generally be convex in a radially inward direction and the outer peripheral surface of the rotor having a plurality of curved recess surfaces, each of the curved recess surfaces contacting the radially inner side curved surface of a corresponding magnet.

6. An electric power steering apparatus comprising:

an electric motor that generates a steering assisting force for supplementing a steering force; and

a steering shaft that receives the steering assisting force, the electric motor including;

a stator, the stator having a plurality of tooth parts, each tooth part having a radially inner side end and a radially outer side end;

a coil provided around each tooth part, the coil being formed into a predetermined shape by being pressed using a press-forming jig;

a yoke having a plurality of dovetail grooves extending along a radially inner peripheral surface of the yoke, the yoke containing the tooth parts and coil, the tooth parts, coil and yoke being integrated by molding using a resin having at least one of adhesion and electric insulation characteristics;

a rotor that rotates in the stator, the rotor having an outer peripheral surface; and

a plurality of permanent magnets disposed on the outer peripheral surface of the rotor, each magnet having a radially inner side surface, a radially outer side surface and a pair of opposite ends, the radially inner side surface of each magnet being curved to generally be convex in a radially inward direction and the outer peripheral surface of the rotor has a plurality of curved recess surfaces, each of the curved recess surfaces contacting the radially inner side curved surface of a corresponding magnet.

7. The electric power steering apparatus according to claim 6, wherein the insulating sheet comprises an electrically insulating material having a thickness substantially equal to an amount of protrusion the protruded portion protrudes from the radially outer side end of each tooth part.

8. The electric power steering apparatus according to claim 6, wherein the coil mounting portion includes a longitudinally extending groove to allow passage of the resin having electric insulation characteristics.

9. The electric power steering apparatus according to claim 6, wherein each tooth part is mounted to the yoke portion by fitting the protruded portion into a corresponding dovetail groove.

10. An electric power steering apparatus comprising:

an electric motor that generates a steering assisting force for supplementing a steering force; and

a steering shaft that receives the steering assisting force, the electric motor including;

a stator, the stator having a plurality of tooth parts, each tooth part having a radially inner side end and a radially outer side end, the radially inner side end of each tooth part having a magnetic pole portion extending in a circumferential direction and a protruded portion protruding in the circumferential direction from the radially outer side end, the magnetic pole portion and protruded portion defining a coil mounting portion wrapped by an insulating sheet;

a coil provided around each tooth part;

a yoke having a plurality of dovetail grooves extending along a radially inner peripheral surface of the yoke, the yoke containing the tooth parts and coil, the tooth parts, coil and yoke being integrated by molding using a resin having at least one of adhesion and electric insulation characteristics;

a rotor that rotates in the stator, the rotor having an outer peripheral surface; and

a plurality of permanent magnets disposed on the outer peripheral surface of the rotor, each magnet having a radially inner side surface, a radially outer side surface and a pair of opposite ends, the radially inner side surface of each magnet being curved to generally be convex in a radially inward direction and the outer peripheral surface of the rotor has a plurality of curved recess surfaces, each of the curved recess surfaces contacting the radially inner side curved surface of a corresponding magnet.