Rotating electric machine and manufacturing method thereof

• US 7,675,206 B2
• Filed: 07/11/2006
• Issued: 03/09/2010
• Est. Priority Date: 09/16/2005
• Status: Expired due to Fees

• Current Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Original Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Inventors: Hemmi, Shinsuke, Akutsu, Satoru, Yamamoto, Kyouhei
• Primary Examiner(s): Leung; Quyen
• Assistant Examiner(s): Gonzalez Quinones; Jose A
• Application Number:
  US11/483,719
• Publication Number:
  US 20070063596A1
• Time in Patent Office: 1,337 Days
• Field of Search: 310/71, 310/89, 310/112, 310/115
• US Class Current: 310/71
• CPC Class Codes: H02K 11/21 Devices for sensing speed or position, or actuated thereby specially adapted for machines having non-mechanical commutating devices H02K29/06, H02K29/14
• CPC Class Codes: H02K 5/22 Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes

Abstract

A rotating electric machine which includes: a stator having a stator core fixed inside a bottomed frame and a stator winding wound around the stator core; a bracket fixed to an opening side of the frame; a rotor having a shaft penetrating the bracket and rotatably supported by a bracket side bearing and by a frame side bearing, the rotor being arranged inside the stator core interposing a gap therebetween; a respective phase lead wire electrically connected to the stator winding and led out from the bracket; a rotation sensor that detects a rotational position of the rotor; and a sensor signal wire connected to the rotation sensor and led out from the bracket. A front end portion of the respective phase lead wire is introduced to inside the bracket from outside an opening portion provided at the bracket, thereby electrically connecting to the stator winding.

Claims

1. A rotating electric machine comprising:

a stator having a stator core fixed inside a bottomed frame and a stator winding wound around the stator core;

a bracket fixed to an opening side of the frame;

a rotor having a shaft penetrating the bracket and rotatably supported by a bracket side bearing fixed to the bracket and by a frame side bearing arranged at the frame, the rotor being arranged inside the stator core interposing a gap therebetween;

a respective phase lead wire electrically connected to the stator winding and led out from the bracket;

a rotation sensor fixed to the bracket that detects a rotational position of the rotor; and

a sensor signal wire connected to the rotation sensor and led out from the bracket, wherein

the respective phase lead wire and the sensor signal wire are led out from portions of the bracket different from each other, and

a front end portion of the respective phase lead wire is introduced to inside the bracket from outside an opening portion provided at the bracket, thereby electrically connecting to the stator winding from outside the bracket,

wherein the respective phase lead wire is inserted though a grommet, the front end portion thereof being introduced to inside the bracket though the opening portion provided at the bracket, and

the grommet is arranged to close the opening portion from outside the bracket and is fixed to the opening portion from outside the bracket by a cover.

2. The rotating electric machine according to claim 1, wherein

the front end portion of the respective phase lead wire introduced to inside the bracket includes a connection terminal, which is electrically connected to a relay board by a screw from outside the bracket though a screwed hole provided at the bracket, the relay board being arranged inside the bracket and connected to the stator winding.

3. The rotating electric machine according to claim 2, wherein

the rotating electric machine is a brushless motor for an electric power steering apparatus,

the bracket of the brushless motor is arranged by being fitted to a housing, which contains a driven shaft transmitted with a rotational force of the brushless motor, and

the screwed hole provided at the bracket is covered by the housing.

4. The rotating electric machine according to claim 1, wherein

the sensor signal wire is inserted through a grommet arranged at a notch portion provided at the bracket, to be led out from the bracket, and

the grommet is pressed in an axial direction by fastening a bolt for fixing the frame to the bracket and is pinched between the bracket and the frame.

5. The rotating electric machine according to claim 1, wherein

the sensor signal wire is connected to the rotation sensor through a connector inside the bracket.

6. The rotating electric machine according to claim 1, wherein

the respective phase lead wire and the sensor signal wire include a plurality of lead wires, and

the lead wires are inserted into hole portions provided at the grommets respectively piece by piece.

7. A method of manufacturing a rotating electric machine, which includes:

a stator having a stator core fixed inside a bottomed frame and a stator winding wound around the stator core;

a bracket fixed to an opening side of the frame;

a rotor having a shaft penetrating the bracket and rotatably supported by a bracket side bearing fixed to the bracket and by a frame side bearing arranged at the frame, the rotor being arranged inside the stator core interposing a gap therebetween;

a respective phase lead wire electrically connected to the stator winding and led out from an opening portion of the bracket;

a rotation sensor fixed to the bracket that detects a rotational position of the rotor; and

a sensor signal wire connected to the rotation sensor and led out from a portion of the bracket different from the portion from which the respective phase lead wire is led out,

the method comprising;

a step of leading out the sensor signal wire from inside to outside the bracket through the portion of the bracket different from the portion from which the respective phase lead wire is led;

a step of covering inside the bracket by the frame and fixing the bracket and the frame; and

a step of introducing a front end portion of the respective phase lead wire from outside the opening portion of the bracket to inside the bracket through the portion of the bracket from which the respective phase lead wire is led out, and electrically connecting the front end portion to the stator winding from outside the bracket.

8. The method of manufacturing a rotating electric machine according to claim 7, further comprising:

a step of inserting the respective phase lead wire through a grommet, introducing the front end portion of the respective phase lead wire to inside the bracket through the opening portion provided at the bracket, arranging the grommet to close the opening portion from outside the bracket, and fixing the grommet to the opening portion from outside the bracket by a cover.