CN113353145A - Electric power steering apparatus and manufacturing method - Google Patents
Electric power steering apparatus and manufacturing method Download PDFInfo
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- CN113353145A CN113353145A CN202110238742.8A CN202110238742A CN113353145A CN 113353145 A CN113353145 A CN 113353145A CN 202110238742 A CN202110238742 A CN 202110238742A CN 113353145 A CN113353145 A CN 113353145A
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- power supply
- electric motor
- holding member
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 14
- 238000004804 winding Methods 0.000 claims description 8
- 230000017525 heat dissipation Effects 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000008054 signal transmission Effects 0.000 description 2
- 230000005856 abnormality Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/30—Structural association with control circuits or drive circuits
- H02K11/33—Drive circuits, e.g. power electronics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D5/00—Power-assisted or power-driven steering
- B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
- B62D5/0403—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by constructional features, e.g. common housing for motor and gear box
- B62D5/0406—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by constructional features, e.g. common housing for motor and gear box including housing for electronic control unit
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D5/00—Power-assisted or power-driven steering
- B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
- B62D5/0403—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by constructional features, e.g. common housing for motor and gear box
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D5/00—Power-assisted or power-driven steering
- B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
- B62D5/0457—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by control features of the drive means as such
- B62D5/046—Controlling the motor
- B62D5/0463—Controlling the motor calculating assisting torque from the motor based on driver input
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D5/00—Power-assisted or power-driven steering
- B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
- B62D5/0457—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by control features of the drive means as such
- B62D5/0481—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by control features of the drive means as such monitoring the steering system, e.g. failures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
- H02K11/21—Devices for sensing speed or position, or actuated thereby
- H02K11/215—Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
- H02K5/225—Terminal boxes or connection arrangements
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2211/00—Specific aspects not provided for in the other groups of this subclass relating to measuring or protective devices or electric components
- H02K2211/03—Machines characterised by circuit boards, e.g. pcb
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Steering Mechanism (AREA)
- Cooling Or The Like Of Electrical Apparatus (AREA)
- Motor Or Generator Frames (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
An electric power steering apparatus and a manufacturing method. An electric power steering device (1) includes a motor housing (200) and a control unit (100). The motor housing (200) includes a motor connection terminal (210) extending toward the control unit (100). The control unit (100) comprises: a connector assembly (110) arranged at a position farthest from the electric motor; a heat sink cover (120) to which the connector assembly is mounted; a driving board (130) arranged so that a surface opposite to a surface on which the driving electronic component is mounted faces a heat sink cover side; a power supply board (150) arranged such that a surface on which the power supply electronic component is mounted faces the drive board side; a board holding member (140) having a holding portion (141) that holds the driving board and the power board at a predetermined distance and disposed between the driving board and the power board; and a control board (160) disposed on the electric motor side with respect to the power supply board in the output shaft direction.
Description
Technical Field
The present invention relates to an electric power steering apparatus and a manufacturing method.
Background
In the related art, there is known a technology related to an electric power steering apparatus provided by integrating an electric motor for driving a steering mechanism of a vehicle and an electric circuit for controlling the electric motor. For example, patent document 1 discloses a novel electric power steering apparatus that suppresses an increase in the size of a housing in which an electronic control apparatus is accommodated in a radial direction, and that reduces the number of parts such as a relay connector as much as possible, and that has a simple heat dissipation structure. The electric power steering apparatus includes: a power supply circuit unit mounted on the metal plate; a power conversion circuit unit mounted on the metal plate; and a control circuit unit mounted on the resin board. A power connector wiring portion that supplies power from the power supply circuit unit to the power conversion circuit unit and the control circuit unit and a signal transmission connector wiring portion that transmits input and output signals to the control circuit unit are embedded in a connector terminal assembly made of synthetic resin and arranged on an outer peripheral side of the metal plate, and connector terminals of the power connector wiring portion and the signal transmission connector wiring portion exposed from the connector terminal assembly are directly connected to connectors of the respective power supply circuit unit, power conversion circuit unit, and control circuit unit.
Patent document 2 discloses an electric power steering apparatus capable of suppressing a wiring space in a structure having a plurality of plates. In the electric power steering apparatus, the connector has a terminal connected to the first plate or the second plate, and is provided on a side opposite to the motor unit with the plate interposed therebetween. When the first plate protrudes in the axial direction of the motor unit, there are two or more non-overlapping regions that do not overlap with the second plate. The at least one non-overlapping area is a connector connection area connected to the connector terminals, and the at least one non-overlapping area other than the connector connection area is a motor electric wire connection area connected to motor electric wires connected to the winding sets of the respective phases. Therefore, the wiring space can be suppressed.
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication No. 2016-144382
Patent document 2: japanese laid-open patent publication No. 2017-189034
Disclosure of Invention
Problems to be solved by the invention
As described above, since the electric power steering apparatus is provided in the engine room of the vehicle, the electric power steering apparatus needs to be as small as possible. On the other hand, since the electric power steering apparatus internally houses electronic components having a very large amount of heat, the electric power steering apparatus is required to have high heat dissipation and also to reduce the manufacturing cost by improving assemblability at the time of manufacturing. However, in the above-described prior art, since the heat sink is positioned in the middle of the device, it cannot be said that the heat dissipation is good, particularly regardless of the case where there are a plurality of boards in the control unit or the control unit is assembled with the electric motor.
The present invention has been devised in view of such circumstances, and provides an electric power steering apparatus having good heat dissipation and good assemblability due to modularization, and a method of manufacturing the electric power steering apparatus.
Means for solving the problems
In order to solve the above problem, there is provided an electric power steering apparatus including: a motor housing configured to house an electric motor for driving a steering mechanism for a vehicle; and a control unit disposed on an opposite side of an output shaft of the electric motor. The motor housing includes a motor connection terminal electrically connected to the electric motor and extending toward the control unit. The control unit includes: a connector assembly disposed at a position farthest from the electric motor and having a plurality of connectors formed to be connected with cables from an outside; a heat sink cover configured to mount the connector assembly and to be fixed to the motor housing; a driving board configured to mount driving electronic components for driving the electric motor, and arranged such that a surface opposite to a surface on which the driving electronic components are mounted faces a heat sink cover side; a power supply board configured to mount power supply electronic parts for generating electric power of the drive board, and arranged on an electric motor side with respect to the drive board in a direction of the output shaft such that a surface on which the power supply electronic parts are mounted faces a drive board side; a board holding member having a receiving portion that receives the driving electronic component and the power supply electronic component and having a holding portion that holds the driving board and the power supply board at a predetermined distance, and disposed between the driving board and the power supply board; and a control board configured to mount a rotation sensor for detecting rotation of the output shaft and a controller for controlling the driving electronic components, and arranged on an electric motor side with respect to the power supply board in a direction of the output shaft such that a surface on which the rotation sensor is mounted faces the electric motor side.
Therefore, by providing a heat sink at an end portion of the device near the drive board where a large amount of heat is generated, arranging the heat sink in direct contact with the outside air, and providing a board holding member between boards in the control unit, it is possible to provide an electric power steering device having good heat dissipation and good assemblability due to modularization.
The board holding member may have a holding member connection terminal connected to the motor connection terminal, and the board holding member may have a function of holding the driving board and the power supply board at the predetermined distance when the motor connection terminal is pushed into the holding member connection terminal so as to assemble the control unit and the motor housing.
Therefore, by having the following functions: holding the driving board and the power supply board at a predetermined distance when pressing the terminals to assemble the control unit and the electric motor can improve assemblability.
The driving board may have a power driving intermediate terminal electrically connected to the power board, and the board holding member may have a function of guiding the power driving intermediate terminal when the power board and the driving board are assembled.
Therefore, when assembling a plurality of boards in the control unit, assemblability can be improved by having a function of guiding terminals for electrically connecting the boards.
One end of the holding portion may be fixed to a surface of the power board on which the power electronic part is mounted, and the other end of the holding portion may be fixed to a surface of the driving board on which the driving electronic part is mounted.
Therefore, it is not necessary to provide a support column for fixing the power supply board to the heat sink cover by the board holding member, and the area of the driving board can be increased.
The connector assembly may include power terminals configured to connect a power cable connected to the connector assembly and the power board, and include control terminals configured to connect a control cable connected to the connector assembly and the control board, and the control terminals may be arranged radially outward of the output shaft with respect to the power terminals.
Therefore, it is not necessary to provide an opening portion for avoiding interference with the control terminal in the power supply board, and it is easy to draw a pattern wiring on the power supply board.
The plate holding member may include a holding member fixing portion configured to fix the control plate from the holding portion to a radially outer side of the output shaft, and the control plate may be fixed to the holding member fixing portion.
Accordingly, the control board is fixed to the board holding member, and therefore, better assemblability is obtained due to modularization.
The radiator cover may include a cover fixing portion configured to fix the control board from the holding portion to a radially outer side of the output shaft, and the control board may be fixed to the cover fixing portion.
Therefore, the control board is fixed to the radiator cover, whereby the misalignment between the sensor detecting the rotation of the output shaft and the center axis of the output shaft can be minimized.
The electric motor may have two windings serving as a redundant system, and the plurality of connectors of the connector assembly, the control board, the drive board, and the power supply board may have a redundant system corresponding to the redundant system of the electric motor.
Therefore, even if there is a redundant system and the number of parts is large, a compact electric power steering apparatus can be provided.
In order to solve the above problem, there is provided a manufacturing method of an electric power steering apparatus including an electric motor for driving a steering mechanism for a vehicle, in which a control unit is disposed on an opposite side of an output shaft of the electric motor. The control unit includes: a heat sink cover secured to a motor housing configured to house the electric motor; a driving board configured to mount driving electronic components for driving the electric motor, and arranged such that a surface opposite to a surface on which the driving electronic components are mounted faces a heat sink cover side; a power supply board configured to mount power supply electronic parts for generating electric power of the drive board, and arranged on an electric motor side with respect to the drive board in a direction of the output shaft such that a surface on which the power supply electronic parts are mounted faces a drive board side; a board holding member having a receiving portion that receives the driving electronic component and the power supply electronic component and having a holding portion that holds the driving board and the power supply board at a predetermined distance, and disposed between the driving board and the power supply board; and a control board configured to mount a rotation sensor for detecting rotation of the output shaft and a controller for controlling the driving electronic components, and arranged on an electric motor side with respect to the power supply board in a direction of the output shaft such that a surface on which the rotation sensor is mounted faces the electric motor side. The manufacturing method comprises the following steps: fitting the driving electronic parts to the receiving portion and fixing the driving board and the board holding member; fixing the driving plate to the heat sink cover on a surface opposite to a surface to which the plate holding member is fixed; fitting the power supply electronic parts to the receiving portion and fixing the power supply board to a surface opposite to a surface of the board holding member to which the driving board is fixed; and fixing the control board to the heat sink cover from the fixed power board side.
Therefore, by providing a heat sink at an end portion of the device near the drive plate where a large amount of heat is generated, arranging the heat sink in direct contact with the outside air, and providing a plate holding member between the plates in the control unit, it is possible to provide a manufacturing method of an electric power steering device having good heat dissipation and good assemblability due to modularization.
Effects of the invention
As described above, according to the present invention, it is possible to provide an electric power steering apparatus having excellent heat dissipation and assemblability, and a method of manufacturing the electric power steering apparatus.
Drawings
Fig. 1 (a) is a plan view of an electric power steering apparatus according to a first embodiment of the present invention, fig. 1 (B) is a right side view thereof, fig. 1 (C) is a front view thereof, fig. 1 (D) is a perspective view thereof viewed from above, and fig. 1 (E) is a perspective view thereof viewed from below.
Fig. 2(a) is a plan view of an electric power steering apparatus according to a first embodiment of the present invention, fig. 2 (B) is a sectional view taken along line B-B of fig. 2(a), and fig. 2 (C) is a sectional view taken along line a-a of fig. 2 (a).
Fig. 3 (a) is an expanded perspective view of the electric power steering apparatus according to the first embodiment of the present invention as viewed from above, and fig. 3 (B) is an expanded perspective view thereof as viewed from below.
Fig. 4 (a) is a plan view of a drive plate of an electric power steering apparatus according to a first embodiment of the present invention, fig. 4 (B) is a right side view thereof, fig. 4 (C) is a front view thereof, and fig. 4 (D) is a perspective view thereof from above.
Fig. 5 (a) is a plan view of a board holding member of an electric power steering apparatus according to a first embodiment of the present invention, fig. 5 (B) is a right side view thereof, fig. 5 (C) is a front view thereof, fig. 5 (D) is a bottom view thereof, and fig. 5 (E) is a perspective view thereof as viewed from above.
Fig. 6 (a) is a plan view of a power supply board of an electric power steering apparatus according to a first embodiment of the present invention, fig. 6 (B) is a right side view thereof, fig. 6 (C) is a front view thereof, fig. 6 (D) is a bottom view thereof, and fig. 6 (E) is a perspective view thereof as viewed from above.
Fig. 7 (a) is a plan view of a control plate of an electric power steering apparatus according to a first embodiment of the present invention, fig. 7 (B) is a right side view thereof, fig. 7 (C) is a front view thereof, fig. 7 (D) is a bottom view thereof, and fig. 7 (E) is a perspective view thereof as viewed from above.
Fig. 8 (a) is a plan view when the drive plate and the plate holding member are fixed in the electric power steering apparatus according to the first embodiment of the present invention, fig. 8 (B) is a right side view, fig. 8 (C) is a front view, fig. 8 (D) is a bottom view, and fig. 8 (E) is a perspective view as viewed from above.
Fig. 9 (a) is a plan view when a portion from a radiator cover to a power supply board is fixed in the electric power steering apparatus according to the first embodiment of the present invention, fig. 9 (B) is a right side view, fig. 9 (C) is a front view, and fig. 9 (D) is a perspective view seen from above.
Fig. 10 (a) is a plan view when a portion from a radiator cover to a control board is fixed in the electric power steering apparatus according to the first embodiment of the present invention, fig. 10 (B) is a right side view, fig. 10 (C) is a front view, and fig. 10 (D) is a perspective view seen from above.
Fig. 11 (a) is a plan view when a portion from a radiator cover to a control board is fixed in the electric power steering apparatus according to the first embodiment of the present invention, fig. 11 (B) is a sectional view taken along line E-E of fig. 11 (a), and fig. 11 (C) is a sectional view taken along line F-F of fig. 11 (a).
Fig. 12(a) is a plan view when a portion from the driving board to the power supply board is fixed in the electric power steering apparatus according to the modification of the first embodiment of the present invention, fig. 12 (B) is a right side view, fig. 12 (C) is a front view, and fig. 12(D) is a perspective view seen from above.
Fig. 13 is a schematic diagram illustrating a relationship between a plate holding member and another plate in an electric power steering apparatus according to a modification of the first embodiment of the present invention.
Fig. 14 is a functional block diagram of an electric power steering apparatus according to an embodiment of the present invention.
Description of the reference numerals
1 electric power steering apparatus
10A/10B first system/second system
100(100A/100B) control unit (first control system/second control system)
110 connector assembly
111 connector
112 power supply terminal
113 control terminal
120 radiator cover
121 cover fixing part
130 drive board
131 driving electronic component
132 power supply drive intermediate terminal
133 fixing hole
140 plate holding member
141 holding part
1421/1422 reception section
143 holding member connecting terminal
144 holding member fixing portion
145 guide hole
146 press-in cap
148 screw protection part
150 power supply board
151 power supply electronic component
152 power control intermediate terminal
153 power terminal connecting hole
160 control panel
161 rotating sensor (MR sensor)
162 controller (Microcomputer)
163 control panel connecting terminal hole
164 control terminal connection hole
200 motor shell
210 motor connection terminal
MTA first electric motor
MTB second electric motor
Output shaft of RT electric motor
Detailed Description
Hereinafter, embodiments according to the present invention will be described with reference to the accompanying drawings.
< first embodiment >
The electric power steering apparatus 1 in the present embodiment will be described with reference to fig. 1 to 14. The electric power steering apparatus 1 includes: a motor case 200 that houses an electric motor MT that drives a steering mechanism for a vehicle; and a control unit 100 disposed on the opposite side of the output shaft RT as the rotor of the electric motor MT. The electric motor MT generates an assist steering torque for a steering mechanism so as to assist the torque when a driver of the vehicle operates to rotate a steering wheel. The control unit 100 is a control device for controlling the electric motor MT that generates the assist steering torque.
In the electric power steering apparatus 1 of the present embodiment, the electric motor MT includes a first electric motor MTA and a second electric motor MTB, and the control unit 100 includes a first control system 100A and a second control system 100B, as shown in fig. 14. In general, the electric power steering apparatus 1 includes: a first system 10A including a first electric motor MTA and a first control system 100A; and a second system 10B comprising a second electric motor MTB and a second control system 100B. As described above, since the two systems are redundant, even if an abnormality occurs in any one of the systems, the control as the electric power steering apparatus 1 can be continued. In the present embodiment, the first electric motor MTA and the second electric motor MTB have a redundant system because the windings include the first winding set and the second winding set and share the rotor. However, the present invention is not limited thereto, and the first electric motor MTA and the second electric motor MTB may be two separate electric motors.
As shown in fig. 1 (a) to 1 (E) and fig. 14, the first control system 100A or the second control system 100B supplies power from the vehicle battery to the power supply electronic part 151 constituting the power supply unit on the power supply board 150 via the cable and the power supply connector 1111. The power connector 1111 is connected to the power terminal 112 formed on the board side of the connector assembly 110. The first control system 100A or the second control system 100B supplies a vehicle speed signal to a microcomputer 162 constituting a controller on the control board 160 via a Car Area Network (CAN) connector 1112, and the CAN connector 1112 is connected to a CAN (not shown) through a control cable. The first control system 100A or the second control system 100B supplies a steering torque signal, a steering angle signal, and the like to the microcomputer 162 via a sensor connector 1113, and the sensor connector 1113 is connected to sensors that detect information of various positions of the vehicle.
The sensor connector 1113 is connected to a control terminal 113 formed on the board side of the connector assembly 110. The control terminal 113 is arranged radially outward of the output shaft RT with respect to the power supply terminal 112. As described above, the control terminal 113 connected to the control board 160 disposed at the distant position is disposed radially outside the power terminal 112 connected to the power board 150 disposed at the near position, and thus, it is not necessary to provide an opening portion for avoiding interference with the control terminal 113 in the power board 150. As a result, the pattern wiring is easily drawn on the power supply board 150.
The driver IC as the driving electronic part 131 on the driving board 130 receives a control signal from the microcomputer 162 on the control board 160, receives driving power from the power supply unit on the power supply board 150, and drives the first electric motor MTA or the second electric motor MTB via its motor connection terminal 210. A magnetic resistance sensor 161(MR sensor) that detects the rotational position of the rotor of the first electric motor MTA or the second electric motor MTB is provided on the control board 160 and inputs the detected motor rotation angle signal to the microcomputer 162. As described above, the connector 111, such as the power connector 1111 and the CAN connector 1112, the control board 160, the drive board 130, and the power board 150 have redundant systems corresponding to the first electric motor MTA and the second electric motor MTB, respectively. As shown in fig. 1 (a), the control unit 100 is arranged while being divided into a first control system 100A and a second control system 100B above and below a center line CT connecting the center of the sensor connector 1113 and the rotation shaft of the electric motor MT. The control unit is arranged in this manner even if there is a redundant system and the number of components is large, whereby a compact electric power steering apparatus 1 can be provided.
The motor housing 200 includes a motor connection terminal 210 electrically connected to the electric motor MT. The motor connection terminal 210 extends toward the control unit 100, is electrically connected to the board, and transmits a driving current for driving the electric motor MT. Since the electric motor MT has three phases, the motor connection terminals 210 include a set of three terminals, and two sets of motor connection terminals corresponding to the first control system 100A and the second control system 100B, respectively, as shown in fig. 2 (B).
As shown in fig. 3 (a) and 3 (B), the control unit 100 includes, in order of being away from a motor case 200 accommodating the electric motor MT, a connector assembly 110, a heat sink cover 120, a driving board 130, a board holding member 140, a power supply board 150, and a control board 160. The connector assembly 110 is disposed at a position farthest from the motor case 200 accommodating the electric motor MT, and is formed with a plurality of connectors 111 connected with cables of a battery, CAN, sensors, and the like from the outside. The connector 111 includes a power connector 1111, a CAN connector 1112, and a sensor connector 1113 corresponding to cables from the outside. The heat sink cover 120 mounts the connector assembly 110 in an area of about 2/3 a of the upper surface, is fixed to the motor housing 200, and dissipates heat generated by the plurality of boards on the remaining upper and side surfaces. The driving plate 130 having a particularly large heat generation amount is disposed in contact with the heat sink cover 120. Since the heat sink cover 120 is separated from the motor housing 200, the heat sink cover is hardly affected by heat generated from the motor MT itself.
In order to drive the electric motor MT, the driving board 130 is mounted with driving electronic parts 131, and the driving electronic parts 131 include: a pre-driver generating a PWM signal from a control signal of the microcomputer 162; a bridge circuit including switching elements that drive the first winding set or the second winding set of the three-phase electric motor MT by PWM signals; shunt resistors for detecting the current of each phase of the bridge circuit, and the like. The driving electronic part 131 may be a driver IC integrating a plurality of functions and circuits into one part, or may be mounted on the driving board 130 as a separate part and circuit. As shown in fig. 4 (a) to 4 (D), the driving board 130 has a power driving intermediate terminal 132 electrically connected to the power board 150. One portion of the power driving intermediate terminal 132 transmits a driving current from the power board 150, and the other portion transmits a control signal from the control board 160 via the power board 150. The driving board 130 is arranged such that a surface on which these driving electronic components 131 are mounted faces the power supply board 150 (board holding member 140) side, and a surface opposite to the surface faces the heat sink cover 120 side. Preferably, the plate of the driving plate 130 is made of metal (particularly, aluminum) in order to easily conduct heat to the heat sink cover 120.
As shown in fig. 6 (a) to 6 (E), the power board 150 is mounted with power electronic components 151 for generating power of the driving board 130. The power supply electronic part 151 constitutes a power supply unit for converting the electric power of the battery obtained through the power supply connector 1111 into electric power suitable for the electric motor MT and the microcomputer 162 on the control board 160. On the surface opposite to the surface on which the power supply electronic parts 151 are mounted, the power supply board 150 has a power supply control intermediate terminal 152 electrically connected to the control board 160. A part of the power control intermediate terminal 152 transmits a control signal from the driving board 130 to the control board 160 via the power board 150, and transmits a signal from the control board 160 to the driving board 130. The power supply board 150 has power supply terminal connection holes 153 at ends connected to the power supply terminals 112. The power supply board 150 is arranged on the electric motor MT side with respect to the drive board 130 in the axial direction of the output shaft RT such that the surface on which the power supply electronic components 151 are mounted faces the drive board 130 side.
As shown in fig. 5 (a) to 5 (E), the board holding member 140 has a receiving portion 1421 for receiving the driving electronic part 131 protruding from the driving board 130 on one surface, and has a receiving portion 1422 for receiving the power supply electronic part 151 protruding from the power supply board 150 on the other surface. The board holding member 140 is disposed between the driving board 130 and the power supply board 150 such that the receiving portion 1421 for receiving the driving electronic component 131 faces the driving board 130 side (the heat sink cover 120 side) and the receiving portion 1422 for receiving the power supply electronic component 151 faces the power supply board 150 side (the motor case 200 side). Since the receiving portions 1421 and 1422 are arranged at positions offset from each other in plan view, the height from the surfaces of the driving electronic component 131 and the power supply electronic component 151 can be absorbed, and the distance in the direction of the rotation axis can be shortened.
The board holding member 140 has holding portions 141 holding the driving board 130 and the power supply board 150 at the four corners of the rectangular portion at a predetermined distance. The predetermined distance is a distance at which the highest one of the driving electronic part 131 and the power supply electronic part 151 does not contact the opposing board. One end of the holding portion 141 is fixed to the surface of the power board 150 on which the power electronic components 151 are mounted, and the other end is fixed to the surface of the driving board 130 on which the driving electronic components 131 are mounted. Therefore, it is not necessary to provide a support column for fixing the power supply board 150 to the heat sink cover 120 by the board holding member 140, and the area of the driving board 130 can be increased.
The board holding member 140 has a holding member connection terminal 143 connected to the motor connection terminal 210. The board holding member 140 includes a holding member connection terminal 143, and the motor connection terminal 210 is connected to the holding member connection terminal 143 so as to assemble the control unit 100 and the motor housing 200, whereby the driving board 130 and the power supply board 150 can be held at a predetermined distance when the motor connection terminal 210 is pushed into the holding member connection terminal 143. As described above, when the motor connection terminal 210 is pressed in order to assemble the control unit 100 and the electric motor MT, the driving board 130 and the power supply board 150 are held at a predetermined distance, whereby assemblability can be improved without applying a load to an assembled part.
The board holding member 140 has a guide hole 145, and when the power board 150 and the driving board 130 are assembled, the guide hole 145 guides the power driving intermediate terminal 132. Since the diameter of the guide hole 145 is larger on the surface on the side of the driving board 130 and smaller on the surface on the side of the power supply board 150, the guide hole has a function of guiding the power supply driving intermediate terminal 132 provided on the driving board 130 when the board is assembled. As described above, when assembling a plurality of boards in the control unit 100, assemblability can be improved by having a function of guiding terminals for electrically connecting the boards. The board holding member 140 includes a press-in cover 146, and the press-in cover 146 serves to protect the holding member connection terminal 143 and guide the motor connection terminal 210 when the motor connection terminal 210 is pushed into the holding member connection terminal 143.
The control board 160 is mounted on one surface with a rotation sensor 161(MR sensor 161) for detecting rotation of the rotation shaft of the electric motor MT, and is mounted on the other surface with a microcomputer 162 (not shown in fig. 7 (a) to 7 (E)) for controlling the driving electronic part 131. The control board 160 is arranged on the electric motor MT side with respect to the power supply board 150 in the axial direction of the output shaft RT such that the surface on which the rotation sensor 161 is mounted faces the electric motor MT side. The control board 160 has a control board connection terminal hole 163 for connecting the power supply control intermediate terminal 152. The control board 160 has a control terminal connection hole 164 connected to the control terminal 113 at an end portion.
As described above, the control unit 100 of the electric power steering apparatus 1 includes: a heat sink cover 120 mounted with the connector assembly 110 disposed at a position farthest from the electric motor MT and fixed to the motor housing 200; a drive board 130 arranged such that a surface opposite to a surface on which the drive electronic components 131 are mounted faces the heat sink cover 120 side; a power supply board 150 disposed on the electric motor MT side with respect to the driving board 130 such that a surface on which the power supply electronic components 151 are mounted faces the driving board 130 side; a board holding member 140 having a receiving portion 1421 or 1422 that receives the driving electronic part 131 and the like and a holding portion 141 that holds the driving board 130 and the power board 150 at a predetermined distance, and disposed between the driving board 130 and the power board 150; and a control board 160 mounted with a controller 162 for controlling the driving electronic part 131 and arranged on the electric motor MT side with respect to the power supply board 150. Therefore, by providing a heat sink at an end portion of the device near the drive board 130 where a large amount of heat is generated, arranging the heat sink in direct contact with the outside air, and providing the board holding member 140 between the boards in the control unit 100, it is possible to provide the electric power steering apparatus 1 having good heat dissipation and good assemblability due to modularization.
Preferably, the control unit 100 is assembled as follows. First, the drive plate 130 and the plate holding member 140 are assembled as shown in fig. 8 (a) to 8 (E). That is, the power driving intermediate terminal 132 of the driving board 130 is inserted while being guided into the guide hole 145 of the board holding member 140, and is fitted to the receiving portion 1421 that receives the driving electronic component 131. The driving plate 130 and the plate holding member 140 are fixed at one end of the holding portion 141.
Subsequently, the driving plate 130 and the plate holding member 140 are integrated, and the driving plate 130 is fixed to the heat sink cover 120 on a surface opposite to the surface to which the plate holding member 140 is fixed. The driving plate 130 has fixing holes 133, and is attached to bosses provided on the heat sink cover 120 by screws via the fixing holes 133. The board holding member 140 has a screw protecting portion 148 at a position corresponding to the fixing hole 133, and is easily attached with a screw.
Subsequently, the power supply board 150 is attached to a portion integrated with each other from the heat sink cover 120 to the board holding member 140, as shown in fig. 9 (a) to 9 (D). That is, the power supply electronic part 151 of the power supply board 150 is fitted to the receiving portion 1422 of the board holding member 140, and the power supply board 150 is fixed at the other end of the holding portion 141 on the surface opposite to the surface of the board holding member 140 to which the driving board 130 is fixed. By doing so, the power control intermediate terminal 152 of the power board 150, the cover fixing portion 121 provided on the heat sink cover 120, and the control terminal 113 protrude from the upper surface of the control unit 100, as shown in these figures.
Subsequently, the control board connection terminal hole 163 and the control terminal connection hole 164 of the control board 160 and the power control intermediate terminal 152 and the control terminal 113 are assembled from the fixed power board 150 side, and the control board 160 is fixed to the cover fixing portion 121 of the heat sink cover 120, as shown in fig. 10 (a) to 10 (D). As described above, the control board 160 is fixed to the heat sink cover 120, whereby the misalignment between the rotation sensor 161 detecting the rotation of the rotation shaft of the electric motor MT and the center of the rotation shaft can be minimized. The method for attaching the control board 160 is not limited thereto. For example, the plate holding member 140 includes a holding member fixing portion 144, the holding member fixing portion 144 is used to fix the control plate 160 from the holding portion 141 to the radially outer side of the output shaft RT, and the control plate 160 may be fixed to the holding member fixing portion 144, as shown in fig. 12(a) to 12 (D). As described above, the control board 160 is fixed to the board holding member 140, whereby better assemblability is obtained due to modularization.
As shown in fig. 10 (a) to 10 (D) and 11 (a) to 11 (C), the rotation sensor 161 is disposed at a position corresponding to a front end of the rotation shaft of the electric motor MT. The holding member connection terminal 143 can be visually observed from the electric motor MT side, the motor connection terminal 210 extending from the motor case 200 to be attached next is connected to the holding member connection terminal 143, and the control unit 100 and the motor case 200 can be attached. As described above, the electric power steering apparatus 1 is completed by attaching the motor housing 200 to the assembled portion from the radiator cover 120 to the control board 160 such that the motor connection terminal 210 and the holding member connection terminal 143 are compatible with each other. Therefore, by providing a heat sink at an end portion of the device near the drive board 130 where a large amount of heat is generated, arranging the heat sink in direct contact with the outside air, and providing the board holding member 140 between the boards in the control unit, it is possible to provide a manufacturing method of the electric power steering apparatus 1 having good heat dissipation and good assemblability due to modularization.
It has been described that the timing of fixing the driving plate 130 to the heat sink cover 120 is when the driving plate 130 and the plate holding member 140 are assembled, and the present invention is not limited thereto. As shown in fig. 12(a) to 12(D), the timing may be when the driving board 130, the board holding member 140, and the power supply board 150 are assembled. In some aspects, the timing may be when the driving board 130, the board holding member 140, the power supply board 150, and the control board 160 are assembled.
In the above description, an example of fixing the control board 160 to the cover fixing part 121 of the heat sink cover 120 has been described, but the present invention is not limited thereto. The control plate 160 may be fixed to the plate holding member 140. For example, the plate holding member 140 includes a holding member fixing portion 144, the holding member fixing portion 144 is used to fix the control plate 160 from the holding portion 141 to the radially outer side of the output shaft RT, and the control plate 160 may be fixed to the holding member fixing portion 144, as shown in fig. 13. As described above, the control board 160 is fixed to the board holding member 140, whereby better assemblability is obtained due to modularization.
The present invention is not limited to the illustrated embodiments, and may be implemented in a configuration without departing from the content described in each claim of the claims. That is, the present invention is mainly illustrated and described with respect to specific embodiments, but various modifications in number and other detailed configurations may be made by those skilled in the art without departing from the scope of the technical idea and purpose of the present invention.
For example, although it has been described that in the electric power steering apparatus 1 of the above embodiment, the electric motor and the control unit are redundant in two systems, the electric motor and the control unit may not be redundant, and the number of redundant systems may be three or more systems.
Claims (9)
1. An electric power steering apparatus comprising:
a motor housing configured to house an electric motor for driving a steering mechanism for a vehicle; and
a control unit disposed on an opposite side of an output shaft of the electric motor,
wherein the motor housing includes a motor connection terminal electrically connected to the electric motor and extending toward the control unit, and
the control unit includes:
a connector assembly disposed at a position farthest from the electric motor and having a plurality of connectors formed to be connected with cables from an outside;
a heat sink cover configured to mount the connector assembly and to be fixed to the motor housing;
a driving board configured to mount driving electronic components for driving the electric motor, and arranged such that a surface opposite to a surface on which the driving electronic components are mounted faces a heat sink cover side;
a power supply board configured to mount power supply electronic parts for generating electric power of the drive board, and arranged on an electric motor side with respect to the drive board in a direction of the output shaft such that a surface on which the power supply electronic parts are mounted faces a drive board side;
a board holding member having a receiving portion that receives the driving electronic component and the power supply electronic component and having a holding portion that holds the driving board and the power supply board at a predetermined distance, and disposed between the driving board and the power supply board; and
a control board configured to mount a rotation sensor for detecting rotation of the output shaft and a controller for controlling the driving electronic components, and arranged on an electric motor side with respect to the power supply board in a direction of the output shaft such that a surface on which the rotation sensor is mounted faces the electric motor side.
2. The electric power steering apparatus according to claim 1,
the board holding member has a holding member connection terminal connected to the motor connection terminal, and the board holding member has a function of holding the driving board and the power supply board at the predetermined distance when the motor connection terminal is pushed into the holding member connection terminal to assemble the control unit and the motor housing.
3. The electric power steering apparatus according to claim 1 or 2, wherein,
the driving board has a power driving intermediate terminal electrically connected to the power board, and
the board holding member has a function of guiding the power supply driving intermediate terminal when the power supply board and the driving board are assembled.
4. The electric power steering apparatus according to claim 1 or 2, wherein,
one end of the holding portion is fixed to a surface of the power supply board on which the power supply electronic part is mounted, and
the other end of the holding portion is fixed to a surface of the driving board on which the driving electronic components are mounted.
5. The electric power steering apparatus according to claim 1 or 2, wherein,
the connector assembly includes power terminals configured to connect a power cable connected to the connector assembly and the power board, and includes control terminals configured to connect a control cable connected to the connector assembly and the control board, and
the control terminal is arranged radially outward of the output shaft with respect to the power supply terminal.
6. The electric power steering apparatus according to claim 1 or 2, wherein,
the plate holding member includes a holding member fixing portion configured to fix the control plate from the holding portion to a radially outer side of the output shaft, and
the control board is fixed to the holding member fixing portion.
7. The electric power steering apparatus according to claim 1 or 2, wherein,
the radiator cover includes a cover fixing portion configured to fix the control board from the holding portion to a radially outer side of the output shaft, and
the control board is fixed to the cover fixing portion.
8. The electric power steering apparatus according to claim 1 or 2, wherein,
the electric motor has two windings serving as a redundant system, and
the plurality of connectors of the connector assembly, the control board, the driving board, and the power board have a redundant system corresponding to a redundant system of the electric motor.
9. A method of manufacturing a control unit in an electric power steering apparatus including an electric motor for driving a steering mechanism for a vehicle, wherein the control unit is disposed on an opposite side of an output shaft of the electric motor,
the control unit includes:
a heat sink cover secured to a motor housing configured to house the electric motor;
a driving board configured to mount driving electronic components for driving the electric motor, and arranged such that a surface opposite to a surface on which the driving electronic components are mounted faces a heat sink cover side;
a power supply board configured to mount power supply electronic parts for generating electric power of the drive board, and arranged on an electric motor side with respect to the drive board in a direction of the output shaft such that a surface on which the power supply electronic parts are mounted faces a drive board side;
a board holding member having a receiving portion that receives the driving electronic component and the power supply electronic component and having a holding portion that holds the driving board and the power supply board at a predetermined distance, and disposed between the driving board and the power supply board; and
a control board configured to mount a rotation sensor for detecting rotation of the output shaft and a controller for controlling the driving electronic parts, and arranged on an electric motor side with respect to the power supply board in a direction of the output shaft such that a surface on which the rotation sensor is mounted faces the electric motor side,
the manufacturing method comprises the following steps:
fitting the driving electronic parts to the receiving portion and fixing the driving board and the board holding member;
fixing the driving plate to the heat sink cover on a surface opposite to a surface to which the plate holding member is fixed;
fitting the power supply electronic parts to the receiving portion and fixing the power supply board to a surface opposite to a surface of the board holding member to which the driving board is fixed; and
the control board is fixed to the heat sink cover from the side of the power board to be fixed.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2020-038102 | 2020-03-05 | ||
| JP2020038102A JP7384709B2 (en) | 2020-03-05 | 2020-03-05 | Electric power steering device and manufacturing method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN113353145A true CN113353145A (en) | 2021-09-07 |
Family
ID=77388878
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202110238742.8A Pending CN113353145A (en) | 2020-03-05 | 2021-03-04 | Electric power steering apparatus and manufacturing method |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP7384709B2 (en) |
| CN (1) | CN113353145A (en) |
| DE (1) | DE102021105227A1 (en) |
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| WO2023207063A1 (en) * | 2022-04-25 | 2023-11-02 | 深圳盈特创智能科技有限公司 | Integrated high-speed brushless direct-current motor |
| CN117601955A (en) * | 2024-01-23 | 2024-02-27 | 域磐科技(江苏)有限公司 | EPS electric control unit compatible with full redundancy and partial redundancy and assembly method |
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- 2021-03-04 DE DE102021105227.0A patent/DE102021105227A1/en active Pending
- 2021-03-04 CN CN202110238742.8A patent/CN113353145A/en active Pending
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| US20020060105A1 (en) * | 2000-10-18 | 2002-05-23 | Tsutomu Tominaga | Electric power steering apparatus |
| CN103921837A (en) * | 2010-04-16 | 2014-07-16 | 株式会社电装 | Motorized Equipment |
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| CN117601955B (en) * | 2024-01-23 | 2024-03-22 | 域磐科技(江苏)有限公司 | EPS electric control unit compatible with full redundancy and partial redundancy and assembly method |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2021141727A (en) | 2021-09-16 |
| JP7384709B2 (en) | 2023-11-21 |
| DE102021105227A1 (en) | 2021-09-09 |
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