1. Field of the Invention
The present invention relates to a motor used in a hydraulic shock absorber absorbing vibrations generated by an engine of a vehicle.
2. Description of the Related Art
A hydraulic shock absorber is used in a vehicle to adjust a valve via which oil travels and/or a diaphragm which makes contact with the oil so as to absorb the vibrations generated by the engine of the vehicle. Such a hydraulic shock absorber typically includes a motor to adjust the valve and/or the diaphragm. The motor used in such an environment in which vibrations and shocks are constantly imposed thereon is required to operate without oil leakage which requires a bearing mechanism that prevents oil leakage. Conventionally, a bearing mechanism is retained by more than two separate components in which a bottom portion of the bearing retaining member is retained by any suitable adhesive, such as caulk.
The motor used in the hydraulic shock absorber must achieve a very high standard of reliability, and therefore, a mechanism for preventing oil leakage of the oil used in the bearing of the motor is essential. Also, the conventional bearing is retained by the bearing retaining member by adhesive which may leak and interfere with the bearing mechanism, which deteriorates the characteristics of the motor. Also, the conventional motor includes the bearing press fitted into the bearing retaining member which causes deformation of the bearing.
In order to overcome the problems described above, preferred embodiments of the present invention provide a motor used in a hydraulic shock absorber to absorb vibrations generated by an engine of a vehicle.
The motor includes a stator portion including an armature, a rotor portion including a field magnet, and a bearing mechanism rotatably supporting the rotor portion with respect to the stator portion centered about the central axis. The bearing mechanism includes a shaft having a substantially cylindrical shape extending in a direction substantially parallel with a direction of transmission of the vibrations generated by an engine to the motor, and affixed to the rotor portion at one end thereof, a sleeve having a substantially tubular shape impregnated with oil and including an inner circumferential surface supporting the shaft, and a sleeve holder including a single component having a cylindrical portion having an inner circumferential surface covering an outer circumferential surface of the sleeve, and a bottom portion covering a lower portion of the cylindrical portion.
Other features, elements, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments thereof with reference to the attached drawings.
Note that in the description of preferred embodiments of the present invention herein, words such as upper, lower, left, right, upward, downward, top, and bottom for describing positional relationships between respective members and directions merely indicate positional relationships and directions in the drawings. Such words do not indicate positional relationships and directions of the members mounted in an actual device. Also note that reference numerals, figure numbers, and supplementary descriptions are shown below to assist the reader in finding corresponding components in the description of the preferred embodiments below to facilitate an understanding of the present invention. It is understood that these expressions in no way restrict the scope of the present invention.
The rotor portion 2 preferably includes a rotor hub 21 having a substantially cylindrical shape with a lid through which an upper portion of a shaft 41 is inserted, and a field magnet 22 preferably arranged at an inner circumferential surface of a cylindrical portion of the rotor hub 21. The stator portion 3 preferably includes a circuit board 31 having an opening at a central portion thereof, a support plate 32 having an opening at a central portion thereof, and an armature 34 preferably arranged near the bearing mechanism 4. Also, a sleeve holder 44 (described below) is arranged at the central portion of the support plate 32. The circuit board 31 is preferably affixed to the support plate 32 preferably via a rivet 33, for example. The armature 34 preferably includes a stator core 341 made by laminating a plurality of silicon steel plates, and a coil 342 formed by winding a wire around teeth of the stator core 341. The armature 34 and the field magnet 22 are arranged opposite to one another in a radial direction. When the motor 1 rotates, a torque centered about the central axis J1 is generated between the armature 34 and the field magnet 22. Note that the shaft 41 may be a portion of the rotor portion 2. Also, the sleeve holder 44 may be a portion of the stator portion 3. A lower end surface of the stator core 341 arranged radially inwardly of the coil 342 makes contact with the sleeve holder 44. With this configuration, an excessive axial movement of the stator core 341 will be restricted by the sleeve holder 44. That is, the stator core 341 is retained by the sleeve holder 44.
The bearing mechanism 4 preferably includes the shaft 41 made of a magnetic material, a sleeve 42 into which the shaft 41 is arranged, a support yoke 43 arranged below the sleeve 42, a chip member 45 preferably having a substantially discoid shape retained by the support yoke 43, and the sleeve holder 44 which preferably covers the sleeve 42 and the support yoke 43. The shaft 41 preferably has a substantially cylindrical shape extending in a substantially parallel direction with respect to a direction of the vibration transmitted to the motor 1 from the engine of the vehicle arranged outside of the motor 1. The shaft 41 is preferably affixed to the rotor hub 21 at an upper portion thereof. The sleeve holder 44 preferably includes a single component having a cylindrical portion 441 which covers an outer circumferential surface of the sleeve 42, and a bottom portion 442 which covers a lower portion of the cylindrical portion. The sleeve holder 44 is preferably affixed at the support plate 32 of the stator portion 3. The bottom portion 442 preferably includes a concave portion 4421. The concave portion 4421 preferably accommodates therein the support yoke 43. The stator core 341 is preferably affixed to the cylindrical portion 441 by press fitting. The sleeve 42 is preferably arranged in the cylindrical portion 441. The sleeve holder 44 is preferably made of an austenite type stainless steel by cutting.
The chip member 45 preferably includes a magnetic chip 451 preferably having a substantially discoid shape, and a thrust plate 452 preferably having a substantially plate shape arranged above the magnetic chip 451. The magnetic chip 451 is fixed in the support yoke 43 preferably having a substantially cylindrical shape, and is retained in the concave portion 4421 of the bottom portion 442. That is, an outer circumferential surface and a bottom surface of the magnetic chip 451 are covered by the support yoke 43. The contact between the shaft 41 which protrudes downwardly from the sleeve 42 and the thrust plate 452 which is made of a resin material is maintained by the magnetic chip 451 which attracts the shaft 41 downwardly. The thrust plate 452 is preferably made of the resin material such as polyether ether ketone (PEEK) or other suitable resin material. The shaft 41 is easily attracted axially downwardly (i.e., in the direction along with the vibrations transmitted to the motor 1 from the engine) by the magnetic chip 451 and the support yoke 43. With this configuration, the rotor portion 2 securely rotates with respect to the stator portion 3.
The sleeve 42 is preferably a porous member impregnated with lubricating oil. The sleeve 42 preferably includes a substantially cylindrical shape having an inner circumferential surface to support the shaft 41 in the radial direction. Preferably, a gap of approximately 0.05 mm to approximately 0.1 mm is provided between the outer circumferential surface of the shaft 41 and the inner circumferential surface of the sleeve 42. When the motor 1 is activated, the outer circumferential surface of the shaft 41 is preferably supported in the radial direction which is substantially perpendicular to the central axis J1 via the lubricating oil by the inner circumferential surface of the sleeve 42. Also, the shaft 41 preferably remains in contact with the thrust plate 452 due to the magnetic chip 451 and the thrust plate 452, and is supported in a thrust direction (i.e., axial direction) at the bottom end thereof. A washer 46 preferably having a substantially annular shape is provided at an upper end surface of the sleeve 42. With this configuration, the lubricating oil impregnated in the sleeve 42 is prevented from leaking above the upper end surface of the sleeve 42.
The support yoke 43 which is preferably made of a magnetic material preferably includes a substantially cylindrical shape with a bottom and retains therein the chip member 45. Note that the magnetic chip 451 of the chip member 45 is polarized in the axial direction such that an upper surface of the magnetic chip 451 includes the characteristics of one of the poles and a lower surface of the magnetic chip 451 includes the characteristics of the other pole. With this arrangement, the shaft 41 is strongly attracted to the magnetic chip 451 in the axial direction. Also, since the magnetic chip 451 is retained inside the support yoke 43 made of the magnetic material, a magnetic flux leakage of the magnetic chip 451 is minimized. Consequently, the force of the magnetic chip 451 attracting the shaft 41 will be improved. Therefore, the shaft 41 is securely prevented from being removed from the sleeve 42 by the vibrations conducted thereto.
The support yoke 43 preferably includes a bottom portion 432 which makes contact with an inner bottom surface of the sleeve holder 44 (that is, a bottom of the concave portion 4421). Also, the support yoke 43 preferably includes an upper end portion 431 which makes contact with the stopper portion 47. The upper end portion 431 includes a flange shape protruding outwardly in the radial direction.
The sleeve 42 is press fitted into the cylindrical portion 441 of the sleeve holder 44 from axially above. A bottom end surface of the sleeve 42 makes contact with a top surface of the washer 472. That is, the stopper portion 47 is securely arranged in the axial direction between the bottom end surface of the sleeve 42 and the upper end portion 431. Also, the support yoke 43 is securely arranged in the axial direction between the bottom end surface of the sleeve 42 (i.e., the stopper portion 47) and the inner bottom surface of the bottom portion 442. That is, the support yoke 43 is affixed in the axial direction with no adhesive.
Note that a distance between the outer circumferential surface of the cylindrically shaped portion of the support yoke 43 and the central axis J1 is preferably less than a distance between the central axis J1 and the inner circumferential surface of the concave portion 4421. Note that a gap is provided between the inner circumferential surface of the concave portion 4421 and the outer circumferential surface of the support yoke 43. With this configuration, deformation which may occur to the sleeve holder 44 when pressing the support yoke 43 thereto is minimized.
Also, the outer circumferential surface of the sleeve 42 preferably includes a step portion 421. Note that a distance between the central axis J1 and a portion of the outer circumferential surface of the sleeve 42 below the step portion 421 is preferably less than that above the step portion 421. Note that the step portion 4412 at the inner circumferential surface of the cylindrical portion 441 is arranged axially above the step portion 421 arranged at the outer circumferential surface of the sleeve 42. When the sleeve 42 is press fitted into the cylindrical portion 441, the contact therebetween is made at the second contact area 4413 at the axial space between the step portion 4412 and the step portion 421. Also, the outer circumferential surface of the sleeve 42 preferably includes a clearance 422 at a portion thereof axially below the step portion 421. As described above, the second contact area 4413 is arranged at the axial space between the pair of the first contact areas 3411. Also, due to the connection among the stator core 341, the cylindrical portion 441 and the sleeve 42, the deformation occurring to the sleeve 42 is minimized.
Also, the sleeve 42 preferably includes at the inner circumferential surface thereof a clearance groove 423 which is a concave portion centered about the central axis J1. Also, the shaft 41 preferably includes a pair of support areas 413 which are arranged apart from one another in the axial direction and by which the shaft 41 is rotatably supported by the sleeve 42. Note that the second contact area 4413 is arranged axially between the pair of support area 413. Due to the connection among the cylindrical portion 441, the sleeve 42 and the shaft 41 as described above, the deformation occurring to the sleeve 42 will not interfere with the shaft 41.
As described above, since the bearing mechanism 4 according to the present preferred embodiment includes the sleeve holder 44 including the single component having the cylindrical portion 441 and the bottom portion 442, even when the vibrations are transmitted thereto, the lubricating oil contained therein is prevented from leaking. Also, the sleeve holder 44 achieves a desirable durability. Also, since the sleeve holder 44 is made by the cutting process, the sleeve holder 44 can be formed precisely regardless of the size thereof, and inexpensively. Also, since the austenite type stainless steel having a low coefficient of linear expansion is preferably used for the sleeve holder 44, the risk of damages (e.g., crack, deformation, etc.) is minimized. Consequently, the motor 1 according to the present preferred embodiment is achieves desirable reliability under various types of environments.
Also, since the sleeve holder 44 is made by the cutting process, the step portion 4412 arranged at the inner circumferential surface of the cylindrical portion 441 can be easily formed. As shown in
Also, as shown in
Also, according to the present preferred embodiment, since the sleeve 42 includes the step portion 421 and the clearance groove 423 and the cylindrical portion 441 of the sleeve holder 44 includes the clearance groove 4411 and the step portion 4412, even when the stator core 341 and/or the sleeve 42 are press fitted into the sleeve holder 44, the deformation of the sleeve 42 is minimized.
As shown in
As shown in
Also, the sleeve 42 preferably includes a clearance groove 423 at the inner circumferential surface thereof in a manner similar to that shown in
While the preferred embodiments of the present invention have been described above in detail, it is understood that variations and modifications will be apparent to those who skilled in the art without departing from the scope and spirit of the present invention.
For example, although the motor 1 shown in
Although the stator core 341 is preferably affixed to the sleeve holder 44 by the protrusions 3412 and the protrusions 4415, the present invention is not limited thereto. For example, a protrusion having a rib shape extending along a substantially parallel direction with the central axis J1 may be arranged at the outer circumferential surface of the sleeve holder 44. Also, instead of the protrusion 4415, the sleeve holder 44 may include at the outer circumferential surface thereof axially above the step portion 421 a protrusion preferably having a substantially rib shape in order to secure the sleeve 42 to the sleeve holder 44.
Although the support area 413 preferably has a cylindrical shape, the present invention is not limited thereto. The inner circumferential surface of the sleeve 42 may include a groove extending substantially perpendicularly to the central axis J1 wherein a portion thereof makes contact with the shaft 41.
Although the sleeve 42, the sleeve holder 44 and the inner circumferential surface of the stator core 341 include an annular shape as shown in
The stator core 341 may be supported in the axial direction by the sleeve holder 44 at a surface other than the lower end surface thereof.
Although the lower end surface of the stator core 341 arranged radially inwardly of the coil 342 makes contact with the sleeve holder 44 in a direct manner, the present invention is not limited thereto. There may be a layer of adhesive between the aforementioned components.
The chip member 45 according to preferred embodiments of the present invention may only include the thrust plate 452. In such a case, the shaft 41 does not need to be made of the magnetic material. Also, the support yoke 43 is not necessarily required.
While preferred embodiments of the invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing the scope and spirit of the invention. The scope of the invention, therefore, is to be determined solely by the following claims.
Number | Date | Country | Kind |
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2007-124273 | May 2007 | JP | national |