CN101410289B - Electric power steering device and method of assembling the same - Google Patents

Abstract

To provide an electric power steering apparatus in which it is possible to minimize a connection distance between a control unit and an electric motor and surely prevent electric noise from mixing between the control unit and the electric motor as well as to minimize electric resistance and minimize an electric loss by directly connecting the control unit and connection terminals of the electric motor and a torque sensor. A motor control apparatus includes a steering column 3 having inserted therein a steering shaft 2 to which steering torque is transmitted, a reduction gear box 4 coupled to the steering shaft 2, and an electric motor 5 that transmits a steering assisting force to the steering shaft 2 via a reduction mechanism in the reduction gear box 4. The electric motor 5 and a control unit 19 including a control board mounted with a control circuit that controls to drive the electric motor 5 are provided side by side in the reduction gear box 4 and a connection terminal of the electric motor 5 is electrically connected to the control unit 19 directly.

Description

Electric power-assisted steering apparatus and assemble method thereof

Technical field

The present invention relates to electric power-assisted steering apparatus and assemble method thereof, described electric power-assisted steering apparatus has: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; And electro-motor, it is passed to this Steering gear by the speed reduction gearing in the reducing gearbox with power steering.

Background technology

As existing electric power-assisted steering apparatus, for example proposing has such electric power-assisted steering apparatus: hold motor in the part of tooth bar case that can hold with being free to slide or install rack shaft or steering box, hold the housing that said motor is carried out the control basal plate of drive controlling, be formed on tooth bar case or the steering box, when the control basal plate of inserting from opening be formed at housing during with the installation base opposed bottom of described opening (boss) butt, the substrate splicing ear that is arranged at control basal plate with (for example be electrically connected from the outstanding motor-side splicing ear that is arranged in the housing of motor with being in contact with one another, with reference to TOHKEMY 2005-329866 communique (below, be called patent documentation 1), TOHKEMY 2005-329867 communique (below, be called patent documentation 2), TOHKEMY 2005-329868 communique (below, be called patent documentation 3), and TOHKEMY 2005-329869 communique (below, be called patent documentation 4)).Here, patent documentation 1 discloses such structure: the substrate-side splicing ear forms the gynetype terminal by the electric conductivity spring leaf, or by forming male type terminal than long electric conductivity plate, the motor-side splicing ear constitutes male type terminal by long electric conductivity plate, or by electric conductivity spring leaf formation gynetype terminal, when control basal plate and installation base butt, the male type terminal of motor-side splicing ear or substrate-side splicing ear, be inserted in the gynetype terminal of substrate-side splicing ear or motor-side splicing ear, the electric conductivity spring leaf of gynetype terminal relies on its spring force and is crimped on the electric conductivity plate of male type terminal, to keep contact each other.

In addition, in recent years, improve the specific consumption of fuel (representing) of vehicle or carry out this requirement of Comprehensive Control and grow to even greater heights, be not only compact car with one liter of fuel mileage, for the big Oversize vehicle that turns to boosting power of needs, also begin to adopt electric power-assisted steering apparatus.In order to strengthen the output of the electro-motor that produces power steering, must increase motor current, but the distribution loss of the motor wire harness that the control unit and the electro-motor of drive controlling electro-motor coupled together also can become big thereupon, and efficient is reduced.

Therefore, known in the past have so electric steering-assisted device: to be close to the opposition side that housing that state is fixed with metal substrate is configured in electro-motor, the outside at housing, and the inboard and the arranged outside radiating fin that are installed in the lid on the electro-motor, inboard at housing and lid, with stepped construction built-in power substrate, big electric current substrate, and control basal plate, be inserted in the electro-motor to the outstanding motor terminal in the lid outside from big electric current substrate, and (for example be electrically connected with electro-motor, with reference to TOHKEMY 2003-267233 communique (below, be called patent documentation 5)).

But, in the conventional example that above-mentioned patent documentation 1～4 is put down in writing, has such structure: in the part of tooth bar case or steering box, hold in the so-called rack-and-pinion electric power-assisted steering apparatus of motor, the motor-side splicing ear is electrically connected with substrate-side splicing ear on being arranged on control basal plate with being in contact with one another, between motor and control basal plate, stay out of the directly assembling of electric connection line ground, thus, between motor and control basal plate, can make distribution length become the shortest, can prevent that electrical noise from sneaking into, and can reduce wiring resistance, reduce electrical loss, but, the moment of torsion detected value of the torque sensor that must detect to the moment of torsion that is delivered on the steering shaft, be input on the control basal plate of control motor, this torque sensor is arranged on the steering handwheel side away from tooth bar case or steering box usually, between this torque sensor and control basal plate, very long connecting cable must be set, thereby there is so unsolved problem: in this connecting cable, can sneak into electrical noise, and, because it is big that resistance becomes, therefore, electrical loss becomes big.

And, for the conventional example of being put down in writing in the above-mentioned patent documentation 1, because electro-motor has the structure of single motor (direct motor), therefore, do not need to be used for electro-motor is connected to phase matched on the speed reduction gearing, but electric power-assisted steering apparatus for cylindricality, because electro-motor and speed reduction gearing spline fitted or serration spline are cooperated, therefore, when being connected to electro-motor on the speed reduction gearing, on one side must make electro-motor self rotation, Yi Bian carry out phase matched, in the case, existing can't corresponding this unsolved problem by the structure in the patent documentation 1.

And, for the conventional example of in above-mentioned patent documentation 1, being put down in writing, if do not set position accurately with the male type terminal of the side in motor-side splicing ear and the substrate-side splicing ear and the opposing party's gynetype terminal, then when connecting, on male type terminal that is in contact with one another with crimped status and gynetype terminal, will produce unrelieved stress, thus aspect the increasing the service life of substrate-side splicing ear and motor-side splicing ear existing problems.On the other hand, if when connecting, do not produce unrelieved stress and set the position of male type terminal and gynetype terminal, then existing problems aspect manufacturing cost accurately.

In addition, for the conventional example of in above-mentioned patent documentation 5, being put down in writing, have following structure: it is stacked to constitute the power substrate of the control setup that electro-motor is controlled, big electric current substrate and control basal plate, and is built in housing and the lid, and this lid is directly installed on the electro-motor; Though in control setup, can generate heat, but electro-motor also is a pyrotoxin, therefore, heating in control setup, the impassabitity electro-motor is delivered on the gear case of the big and reductor that face area is also big of heat absorption capacity efficiently, as its countermeasure, improves thermal diffusivity by radiating fin is set, but, just there is this unsolved problem that to avoid control setup to maximize for radiating fin is set.

Summary of the invention

Therefore, the present invention is conceived to the unsolved problem of above-mentioned conventional example and finishes, its the 1st purpose is to provide a kind of electric power-assisted steering apparatus, it is by directly assembling the splicing ear of control unit and electro-motor and torque sensor, make between control unit and the electro-motor to be connected distance the shortest, can prevent to sneak between the two electrical noise reliably, and can make the resistance minimum, making electrical loss is Min..

In addition, the 2nd purpose of the present invention is to provide a kind of electric power-assisted steering apparatus, and it can easily carry out being electrically connected between control unit and the electro-motor, and can make connection distance between the two the shortest, make the wiring resistance minimum, and can prevent reliably that electrical noise from sneaking into.

And the 3rd purpose of the present invention is to provide a kind of electric power-assisted steering apparatus, and it can easily carry out the phase matched of the worm shaft of the output shaft of electro-motor and Worm gear mechanism.

In addition, the 4th purpose of the present invention is to provide a kind of electric power-assisted steering apparatus, it can realize the prolongation in the service life of substrate-side splicing ear and motor-side splicing ear simultaneously, and the reduction of manufacturing cost, and can make connection distance between the two the shortest, make the wiring resistance minimum, and can prevent reliably that electrical noise from sneaking into.

And, the 5th purpose of the present invention is to provide a kind of electric power-assisted steering apparatus and assemble method, can in the motor wire harness that omits between electro-motor and the control unit, will be delivered to efficiently on the reducing gearbox, and can realize miniaturization and in the heating on the control unit.

For reaching above-mentioned the 1st purpose, the described electric power-assisted steering apparatus in the present invention the 1st aspect has: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; Reducing gearbox, it is connected on this Steering gear; And electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in this reducing gearbox with power steering, it is characterized in that,

On above-mentioned reducing gearbox, be set side by side with above-mentioned electro-motor and control unit, above-mentioned control unit comprises the control basal plate that control circuit is installed, above-mentioned control circuit is used for the above-mentioned electro-motor of drive controlling, directly is electrically connected with the splicing ear of above-mentioned electro-motor on above-mentioned control unit.

Aspect this present invention the 1st in the described invention, by control unit is set on reducing gearbox, the splicing ear of electro-motor can be directly electrically connected on the control unit, can make between control unit and the electro-motor to be electrically connected length the shortest, reduce sneaking into of electrical noise, and, can make the wiring resistance minimum, reduce electrical loss.In addition, owing to do not need to be provided with the motor wire harness between electro-motor and control unit, therefore, the noise that radiates from the motor wire harness will reduce, and can alleviate the influence to radio noise.

In addition, the described electric power-assisted steering apparatus in the present invention the 2nd aspect has: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; Reducing gearbox, it is connected on this Steering gear; And electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in this reducing gearbox with power steering, it is characterized in that,

On above-mentioned reducing gearbox, be set side by side with above-mentioned electro-motor and control unit, above-mentioned control unit comprises the control basal plate that control circuit is installed, above-mentioned control circuit is used for the above-mentioned electro-motor of drive controlling, on above-mentioned control unit, directly be electrically connected with the splicing ear of above-mentioned electro-motor, and, be loaded on the splicing ear of the torque sensor in the above-mentioned reducing gearbox in directly being electrically connected with.

Aspect this present invention the 2nd in the described invention, by control unit is arranged on the reducing gearbox, can be with the splicing ear of electro-motor and the splicing ear of torque sensor, be directly electrically connected on the control unit, can make between control unit and electro-motor and the torque sensor to be electrically connected length the shortest, can make electrical noise sneak into minimizing, and can make the wiring resistance minimum, reduce electrical loss.

And, the described electric power-assisted steering apparatus in the present invention the 3rd aspect, the described invention in the 1st or the 2nd aspect is characterized in that according to the present invention, above-mentioned reducing gearbox is made of the high thermal conductivity material.

Aspect this present invention the 3rd, in the described invention,, therefore, can strengthen heat absorption capacity, radiating effect is improved because reducing gearbox is made of the high thermal conductivity material.

In addition, the described electric power-assisted steering apparatus in the present invention the 4th aspect, the described invention in the 3rd aspect is characterized in that according to the present invention, above-mentioned reducing gearbox constitutes by in aluminium, aluminum alloy, magnesium and the magnesium alloy any carried out casting forming.

Aspect this present invention the 4th, in the described invention, can when keeping high thermal conductivity, easily carry out the making of reducing gearbox.

And, the described electric power-assisted steering apparatus in the present invention the 5th aspect, each the described invention according to the present invention in the 1st to the 4th aspect is characterized in that, above-mentioned control unit with the contact surface of above-mentioned reducing gearbox on have heat-radiating substrate.

Aspect this present invention the 5th, in the described invention, the heating on the control unit can be dispelled the heat to the big reducing gearbox of caloic (heat mass) by heat-radiating substrate.

In addition, the described electric power-assisted steering apparatus in the present invention the 6th aspect, each the described invention according to the present invention in the 1st to the 5th aspect is characterized in that, above-mentioned reducing gearbox has at least: the worm screw incorporating section, and it takes in the output shaft bonded assembly worm screw with above-mentioned electro-motor; The worm gear incorporating section, it is taken in and above-mentioned steering shaft bonded assembly worm gear; And torque sensor incorporating section, it is connected with above-mentioned worm gear incorporating section, be used to take in above-mentioned torque sensor, and be connected with Steering gear, peripheral part in above-mentioned worm screw incorporating section, worm gear incorporating section and torque sensor incorporating section is formed with the control unit installation portion that above-mentioned control unit is installed.

Aspect this present invention the 6th in the described invention, because the control unit installation portion is formed on the peripheral part of worm screw incorporating section, worm gear incorporating section and torque sensor incorporating section, therefore, can make control unit near electro-motor and torque sensor, can easily carry out being electrically connected of control unit and electro-motor and torque sensor.

And, the described electric power-assisted steering apparatus in the present invention the 7th aspect, the described invention in the 6th aspect according to the present invention, it is characterized in that, front end with above-mentioned torque sensor incorporating section, the contraction stopper section of the Steering gear during as crumple is installed in the endface position of the contraction stopper section side of the control unit on the above-mentioned control unit installation portion, is set to than shrinking the stopper section more by worm gear incorporating section side.

Aspect this present invention the 7th in the described invention, because the contraction stopper section of Steering gear during as crumple with the front end of torque sensor incorporating section, be installed in the endface position of the contraction stopper section side of the control unit on the control unit installation portion, be set to than shrinking the stopper section more by worm gear incorporating section side, therefore, when crumple, can prevent the interference between moving bodys such as Steering gear and the control unit reliably.

In addition, the described electric power-assisted steering apparatus in the present invention the 8th aspect, each described invention according to the present invention in the 1st to the 7th aspect, it is characterized in that, above-mentioned electro-motor with above-mentioned control unit near and opposed position on, the motor-side connecting portion is at least to forming highlightedly with axial direction of intersecting, above-mentioned control unit with above-mentioned electro-motor near and opposed position on, be formed with the cell side connecting portion that contacts with said motor side connecting portion face.

According to this described invention in the present invention the 8th aspect, since electro-motor with control unit near and opposed position on the outstanding motor-side connecting portion that forms, on and the opposed position approaching of control unit, form the cell side connecting portion that contacts with motor-side connecting portion face with electro-motor, therefore, can by near and the motor-side of face contact connect end and cell side connecting portion and carry out being connected between electro-motor and the control unit, can make electrical connection length minimum between the two, make the wiring resistance minimum, and can prevent reliably that electrical noise from sneaking into, and do not need to form the big splicing ear of rigidity, can further improve assembleability.

And, the described electric power-assisted steering apparatus in the present invention the 9th aspect, the described invention in the 8th aspect is characterized in that according to the present invention, said motor side connecting portion and said units side connecting portion are made of the either party in splicing ear and the terminal base.

Aspect this present invention the 9th, in the described invention,, therefore,, can easily carry out both connections by terminal and the terminal base of being connected because motor-side connecting portion and cell side connecting portion are made of the either party in splicing ear and the terminal base.

In addition, the described electric power-assisted steering apparatus in the present invention the 10th aspect, the described invention in the 8th or the 9th aspect is characterized in that according to the present invention, and said motor side connecting portion forms with the bus that brush or coil is carried out distribution in the inside of above-mentioned electro-motor.

Aspect this present invention the 10th in the described invention,, therefore, can make electrical path the shortest because the motor-side connecting portion forms with the bus that brush or coil is carried out distribution in the inside of electro-motor.

And, the described electric power-assisted steering apparatus in the present invention the 11st aspect, each described invention according to the present invention in the 8th to the 10th aspect, it is characterized in that, said motor side connecting portion and cell side connecting portion, making under both face state of contact, fix by fasteners such as screw, bolt and rivets.

Aspect this present invention the 11st, in the described invention, fix motor-side connecting portion and cell side connecting portion, can make both electrical connections firm thus by fastener.

In addition, the described electric power-assisted steering apparatus in the present invention the 12nd aspect, each the described invention according to the present invention in the 8th to the 10th aspect is characterized in that, said motor side connecting portion and cell side connecting portion are fixed by welding means such as fusion, spot welding, TIG welding.

Aspect this present invention the 12nd, in the described invention,, therefore, can make electrical connection between the two more firm owing to fix motor-side connecting portion and cell side connecting portion by the welding means.

And, the described electric power-assisted steering apparatus in the present invention the 13rd aspect, each described invention according to the present invention in the 8th to the 10th aspect, it is characterized in that, said motor side connecting portion and cell side connecting portion are made of the male type terminal and the gynetype terminal that can load and unload from the circumferencial direction of above-mentioned electro-motor.

Aspect this present invention the 13rd in the described invention, because motor-side connecting portion and cell side connecting portion, constitute by the male type terminal and the gynetype terminal that can load and unload from the circumferencial direction of electro-motor, therefore, when being installed to electro-motor on the reducing gearbox, even make electro-motor self rotation, male type terminal and gynetype terminal can not sustain damage yet, and can easily carry out the installation of electro-motor.

In addition, the described electric power-assisted steering apparatus in the present invention the 14th aspect, each described invention according to the present invention in the 8th to the 13rd aspect, it is characterized in that the attachment face at above-mentioned reducing gearbox that the contact surface of said motor side connecting portion and cell side connecting portion is configured to above-mentioned electro-motor is same plane.

Aspect this present invention the 14th in the described invention, because the attachment face with respect to above-mentioned reducing gearbox that the contact surface of motor-side connecting portion and cell side connecting portion is configured to electro-motor is same plane, therefore, when being installed to electro-motor on the reducing gearbox, even make electro-motor self rotation, motor-side connecting portion and cell side connecting portion can not interfered mutually yet, can easily carry out the installation of electro-motor.

And, the described electric power-assisted steering apparatus in the present invention the 15th aspect, each described invention according to the present invention in the 8th to the 14th aspect, it is characterized in that, said motor side connecting portion sees from the side and forms L word shape, and it is by forming along the axial board of above-mentioned electro-motor and from the outstanding board that the front end edge radial direction of this board prolongs.

Aspect this present invention the 15th in the described invention, because the motor-side connecting portion is by forming L word shape along axial board and outstanding board, therefore by guaranteeing elasticity along the kink between axial board and the outstanding board, so the unrelieved stress that produces in the time of can relaxing terminal and be connected with terminal base can prolong service life of motor-side connecting portion.

And, the described electric power-assisted steering apparatus in the present invention the 16th aspect, each described invention according to the present invention in the 8th to the 12nd aspect, it is characterized in that, either party in said motor side connecting portion and the said units side connecting portion is made of the terminal clamp of the word of falling L shape, this terminal clamp has: the radial direction board, and its outer peripheral face from above-mentioned electro-motor prolongs along radial direction; With axial board, its front end and axially parallel ground from this radial direction board prolongs, the opposing party of said motor side connecting portion and cell side connecting portion is made of the terminal base with axial contact surface, and the face towards the outer peripheral face of electro-motor of this axial contact surface and above-mentioned axial board contacts.

Aspect this present invention the 16th in the described invention, because the either party in motor-side connecting portion and the cell side connecting portion is made of the terminal clamp of the word of falling L shape, the opposing party is made of the terminal base with axial contact surface, the face towards the outer peripheral face of electro-motor of this axial contact surface and axial board contacts, therefore, can reduce the height of motor-side connecting portion and cell side connecting portion.

In addition, the described electric power-assisted steering apparatus in the present invention the 17th aspect, each described invention according to the present invention in the 8th to the 12nd aspect, it is characterized in that, either party in said motor side connecting portion and the said units side connecting portion is formed with the terminal board that is installed in each flexible cable front end by the many flexible cables of deriving from peripheral part, the opposing party in said motor side connecting portion and the said units side connecting portion is made of terminal base, this above-mentioned electro-motor in terminal base upper edge axially be formed with the contact surface that contacts with above-mentioned terminal board.

Aspect this present invention the 17th in the described invention, because the either party in motor-side connecting portion and the cell side connecting portion, constitute by flexible cable and terminal board, therefore, even there is error in the position that is provided with of motor-side connecting portion and cell side connecting portion, also both can be electrically connected reliably.

And, the described electric power-assisted steering apparatus in the present invention the 18th aspect, each described invention according to the present invention in the 8th to the 12nd aspect, it is characterized in that, either party in said motor side connecting portion and the said units side connecting portion is by forming with lower member: the cable guide part, be equipped with a plurality of radial direction boards that prolong along the radial direction of above-mentioned electro-motor in it; Many flexible cables, they are fixed in each radius direction plate portion of this cable guide part by the joint piece connection; And the terminal board, it is installed in the front end of this flexible cable, and the opposing party in said motor side connecting portion and the cell side connecting portion is made of terminal base, axially is formed with the contact surface that contacts with above-mentioned terminal board at this above-mentioned electro-motor in terminal base upper edge.

Aspect this present invention the 18th in the described invention, make either party in motor-side connecting portion and the cell side connecting portion by forming with lower member: the cable guide part, be equipped with a plurality of radial direction boards that prolong along the radial direction of electro-motor in it; Many flexible cables, they are fixed in each radius direction plate portion of this cable guide part by the joint piece connection; And the terminal board, it is installed in the front end of this flexible cable, therefore, even there is error in the position that is provided with of motor-side connecting portion and cell side connecting portion, also both can be electrically connected reliably.

In addition, the described electric power-assisted steering apparatus in the present invention the 19th aspect, the described invention in the 18th aspect is characterized in that according to the present invention, above-mentioned cable guide part is formed with and makes many flexible cable non-conductive insulation gap walls.

Aspect this present invention the 19th in the described invention, owing to flexible cable is insulated by the insulation gap wall that is arranged on the cable guide part, therefore, even use the flexible cable that is equipped with conductor in periphery, also can prevent from reliably between flexible cable, to be short-circuited.

And, the described electric power-assisted steering apparatus in the present invention the 20th aspect, each described invention according to the present invention in the 17th to the 19th aspect, it is characterized in that, above-mentioned terminal base is formed with the insulation gap wall on the contact surface of the above-mentioned terminal board of contact, this insulation gap wall makes adjacent terminal board insulation.

Aspect this present invention the 20th, in the described invention,, therefore, can make between the terminal board and insulate, can prevent short circuit between the two reliably owing on terminal base, also be formed with the insulation gap wall.

In addition; the described electric power-assisted steering apparatus in the present invention the 21st aspect; each described invention according to the present invention in the 16th to the 20th aspect; it is characterized in that; described electric power-assisted steering apparatus has protective case; this protective case covers both under the state that said motor side connecting portion and said units side connecting portion couple together, and the height and position of this protective case is selected in below the height and position of above-mentioned control unit.

Aspect this present invention the 21st in the described invention; because motor-side connecting portion and cell side connecting portion protected cover under the state that couples together covers, and therefore, can guarantee the electrical connection of motor-side connecting portion and cell side connecting portion; and; because the height and position of protective case is selected in below the height and position of control unit, therefore, protective case can be more not outstanding than control unit; can easily carry out assembling operation; and, when crumple, can prevent reliably that protective case from contacting with moving-member.

And, the described electric power-assisted steering apparatus in the present invention the 22nd aspect, each described invention according to the present invention in the 8th to the 21st aspect, it is characterized in that, above-mentioned control unit has synthetic resin system framework, this synthetic resin system framework with the splicing ear and the opposed position of the either party in the terminal base of above-mentioned electro-motor, the installation board across being fixed on the above-mentioned reducing gearbox is formed with the opposing party in splicing ear and the terminal base.

Aspect this present invention the 22nd in the described invention, because on the opposed position of either party in synthetic resin system framework and splicing ear above-mentioned electro-motor and the terminal base, across the installation board that is fixed on the above-mentioned reducing gearbox, be formed with the opposing party in splicing ear and the terminal base, therefore, can prevent splicing ear or terminal base because of vibration of vehicle produces the vibration different with reducing gearbox, be suppressed at splicing ear and terminal base place and produce stress concentration.

In addition, the described electric power-assisted steering apparatus in the present invention the 23rd aspect has: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; Reducing gearbox, it is connected on this Steering gear; And electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in this reducing gearbox with power steering, it is characterized in that,

In the above-mentioned reducing gearbox Worm gear mechanism is housed, this Worm gear mechanism has: worm shaft, and it is connected with the output shaft of above-mentioned electro-motor; Worm gear, itself and the worm mesh that is formed on this worm shaft, and be connected on the steering shaft, the control unit side splicing ear of the motor-side splicing ear of above-mentioned electro-motor and above-mentioned control unit, be formed near the motor mounting flange of above-mentioned reducing gearbox, overlap in the axial direction, and constitute and to contact by face, with after above-mentioned worm shaft begins to be connected, said motor side splicing ear contacts with the mode face that overlaps in the axial direction with above-mentioned control unit side splicing ear at the output shaft of above-mentioned electro-motor.

Aspect this present invention the 23rd in the described invention, at the output shaft of electro-motor with before worm shaft begins to be connected, motor-side splicing ear and control unit side splicing ear do not overlap in the axial direction, thus, even self along the circumferential direction rotates electro-motor, motor-side splicing ear and control unit side splicing ear can not interfere yet, and can easily carry out the output shaft of electro-motor and being connected of worm shaft.

And, the described electric power-assisted steering apparatus in the present invention the 24th aspect, the described invention in the 23rd aspect is characterized in that according to the present invention, and the distance of establishing from the shell-side end face that is formed at the motor flange on the above-mentioned electro-motor to the front end of said motor side splicing ear is L4; If the distance from the motor-side end face of the motor mounting flange that is formed at above-mentioned reducing gearbox to the motor-side end face of above-mentioned worm shaft is L5; If the distance from the motor-side end face of said motor mounting flange to the front end of above-mentioned control unit side splicing ear is L6; If the distance from the shell-side end face of said motor flange to the front end face of the output shaft of above-mentioned electro-motor is L7, at this moment, satisfy (L4+L5+L6)＜L7.

Aspect this present invention the 24th in the described invention, the distance of establishing from the shell-side end face that is formed at the motor flange on the electro-motor to the front end of motor-side splicing ear is L4; If the distance from the motor-side end face of the motor mounting flange that is formed at gear hub to the motor-side end face of the worm shaft of worm mechanism is L5; If the distance from the motor-side end face of motor mounting flange to the front end of control unit side splicing ear is L6; Make distance L 4, L5, L6's and less than distance L 7 from the shell-side end face of motor flange to the front end face of the output shaft of electro-motor, thereby, with before the worm shaft of Worm gear mechanism cooperates, the motor-side splicing ear can not overlap with control unit side splicing ear at the output shaft of electro-motor.Therefore can easily carry out the phase matched of the worm shaft of the output shaft of electro-motor and Worm gear mechanism.

In addition, the described electric power-assisted steering apparatus in the present invention the 25th aspect, the described invention in the 24th aspect according to the present invention, it is characterized in that, the length of fit of the output shaft of above-mentioned electro-motor and the worm shaft of above-mentioned Worm gear mechanism is less than the motor body of above-mentioned electro-motor and the tongue and groove length of fit of above-mentioned reducing gearbox.

Aspect this present invention the 25th in the described invention, the length of fit of the output shaft by making electro-motor and the worm shaft of Worm gear mechanism, less than the motor body of electro-motor and the tongue and groove length of fit of gear hub, even at (axial length of motor body very long situation under) under the very big situation of the quality of electro-motor, because from the installation length of the outstanding electro-motor of gear hub is not correspondingly to become so big, therefore, except the effect of the invention described in the present invention the 24th aspect, can also be installed on the gear hub by the electro-motor that quality is big.

And the described electric power-assisted steering apparatus in the present invention the 26th aspect has: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; Reducing gearbox, it is connected on this Steering gear; And electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in this reducing gearbox with power steering, it is characterized in that,

On above-mentioned reducing gearbox, be set side by side with: above-mentioned electro-motor; And control unit, it comprises the control basal plate that control circuit is installed, above-mentioned control circuit is used for the above-mentioned electro-motor of drive controlling, on the position of the approaching above-mentioned control unit of above-mentioned electro-motor, form the motor-side splicing ear, on the position of the approaching above-mentioned electro-motor of above-mentioned control unit, form control unit side splicing ear, by at least one side at least one side that predetermined dimension limit ground forms said motor side splicing ear and above-mentioned control unit side splicing ear is set at above-mentioned electro-motor and above-mentioned control unit, said motor side splicing ear and above-mentioned control unit side splicing ear are provided with opposed mutually with gap, make one of above-mentioned control unit side splicing ear and said motor side splicing ear squarely become such flexible structure: on the opposing party's of above-mentioned control unit side splicing ear and said motor side splicing ear direction, elastic deformation taking place by making it, absorb above-mentioned gap, thereby contact with above-mentioned the opposing party, make the opposing party of above-mentioned control unit side splicing ear and said motor side splicing ear form the rigid construction that can not deform towards a side of above-mentioned control unit side splicing ear and said motor side splicing ear.

Aspect this present invention the 26th in the described invention, owing to make at least one square flexible structure that becomes of motor-side splicing ear and substrate-side splicing ear, make the opposing party form rigid construction, by making a side elastic deformation takes place with both electrical connections, therefore, do not need motor-side splicing ear and substrate-side splicing ear are configured on the high-precision position, do not need to make motor-side splicing ear and substrate-side splicing ear to form flexible structure, therefore, can realize the reduction of manufacturing cost.

In addition, the described electric power-assisted steering apparatus in the present invention the 27th aspect, the described invention in the 26th aspect according to the present invention, it is characterized in that, leading section a side of above-mentioned control unit side splicing ear that forms above-mentioned flexible structure and said motor side splicing ear forms slotted hole, on the opposing party of above-mentioned control unit side splicing ear that forms rigid construction and said motor side splicing ear, form tapped bore, make a side and the opposing party's of above-mentioned control unit side splicing ear and said motor side splicing ear above-mentioned tapped bore and above-mentioned slotted hole correspondence, fix screw is passed above-mentioned slotted hole to screw in the above-mentioned tapped bore, thus, above-mentioned control unit side splicing ear and the electrical connection of said motor side splicing ear are got up.

Aspect this present invention the 27th in the described invention, side at substrate-side splicing ear that is electrically connected by fix screw and motor-side splicing ear, be formed with the slotted hole that passes fix screw, by forming this slotted hole, can absorptive substrate side splicing ear and the fluctuation the during manufacturing of motor-side splicing ear, therefore, can further realize the reduction of manufacturing cost.

And, electric power-assisted steering apparatus described in the present invention the 28th aspect, the described invention in the 26th or the 27th aspect according to the present invention, it is characterized in that, form the above-mentioned control unit side splicing ear of flexible structure and a side of said motor side splicing ear and see the parts that form L word shape from the side, it is made of following position: the 1st elasticity position, and its opposing party towards above-mentioned control unit side splicing ear and said motor side splicing ear extends; And the 2nd elasticity position, it is from the front end at the 1st elasticity position, is extending on the direction of the opposing party's of above-mentioned control unit side splicing ear and said motor side splicing ear joint face.

Aspect this present invention the 28th in the described invention, even between motor-side splicing ear and substrate-side splicing ear, have the gap, by making a side who forms L word shape of substrate-side splicing ear and motor-side splicing ear, elastic deformation is taking place on the opposing party's of substrate-side splicing ear and motor-side splicing ear direction, can when absorbing the gap, it be electrically connected on the opposing party, therefore, unrelieved stress in the time of can relaxing being connected of motor-side splicing ear and substrate-side splicing ear can realize the long lifetime of motor-side splicing ear and substrate-side splicing ear.

In addition, the described electric power-assisted steering apparatus in the present invention the 29th aspect, the described invention in the 28th aspect according to the present invention, it is characterized in that, said motor side splicing ear, be formed on above-mentioned electro-motor the motor-side flange near, this motor-side flange is connected with gear box side flange on being arranged on above-mentioned reducing gearbox, above-mentioned control unit side splicing ear, be formed on the above-mentioned control unit that is fixed in above-mentioned reducing gearbox, and be configured in above-mentioned reducing gearbox side flange near, above-mentioned the 1st elasticity position that constitutes a side of above-mentioned control unit side splicing ear and said motor side splicing ear is set to such length: the 1st elasticity position can be than the flange surface of above-mentioned reducing gearbox side flange, or the flange surface of said motor side flange is more outstanding.

Aspect this present invention the 29th in the described invention, because motor-side splicing ear and substrate-side splicing ear are can be from the forwards outstanding structure of flange surface separately, therefore, can be when making when assembling control unit and electro-motor because of interfering, damage the breakage that causes, function deterioration preventing mutually in possible trouble.

And the described electric power-assisted steering apparatus in the present invention the 30th aspect has: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; Torque sensor, it detects above-mentioned steering torque; Electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in the reducing gearbox with power steering; And control unit, its basis is come the above-mentioned electro-motor of drive controlling by the detected steering torque of above-mentioned torque sensor, it is characterized in that,

Above-mentioned torque sensor, above-mentioned electro-motor and above-mentioned control unit are assembled on the above-mentioned reducing gearbox, above-mentioned electro-motor is made of brushless motor, it has and the outside electric contact that is connected usefulness of motor coil bonded assembly, above-mentioned control unit has the electric contact bonded assembly electric contact with above-mentioned electro-motor, under the state that above-mentioned electro-motor and above-mentioned control unit is assembled on the above-mentioned reducing gearbox, the electric contact of this electro-motor and the electric contact of this control unit are configured in the position that is connected to each other directly, and the mode that the heating that produces when will above-mentioned electro-motor be switched on control of above-mentioned control unit is directly delivered on the above-mentioned reducing gearbox is assembled on this reducing gearbox.

Aspect this present invention the 30th in the described invention, owing to respectively electro-motor and control unit are assembled on the reducing gearbox that heat absorption capacity is big and face area is big, therefore, can be delivered to the heating of control unit on the reducing gearbox efficiently, the radiating fin of control unit can be reduced or omit as much as possible, the miniaturization and of electric power-assisted steering apparatus can be realized.

In addition, because the output stage of motor coil and control unit can not be connected by bunch ground, therefore, can omit the bunch that is used for motor energising, small-sized weight-saving, cheaply and reduced the high efficiency electric power-assisted steering apparatus of distribution loss can be provided.

And, because electro-motor is a brushless motor, therefore, the not loss that causes because of the contact resistance of brush, the bunch that is used for the motor energising with omission combines, electric power-assisted steering apparatus can be applied in needs in the big Oversize vehicle that turns to augmented thrust, and this big augmented thrust that turns to is only all can not obtain with either party's low loss means.

In addition, being applied under the situation that does not need big medium-sized, the compact car that turns to augmented thrust,, therefore, can make electro-motor and control unit than present situation miniaturization more because loss is very little.

In addition, the described electric power-assisted steering apparatus in the present invention the 31st aspect, the described invention in the 30th aspect according to the present invention, it is characterized in that, above-mentioned electro-motor has the rotor angle detector, this rotor angle detector is used to detect the corner of the rotor that is provided in the output shaft side, and has the outside electric contact that connects usefulness, above-mentioned control unit has the electric contact bonded assembly electric contact with above-mentioned rotor angle detector, under the state that above-mentioned electro-motor and above-mentioned control unit is assembled on the above-mentioned reducing gearbox, the electric contact of above-mentioned rotor angle detector and the electric contact of above-mentioned control unit are provided in the position that is connected to each other directly.

Aspect this present invention the 31st in the described invention, can be with the electric contact direct connection of signal that is connected the electric contact on the rotor angle detector and is used for receiving the rotor angle detector of control unit, therefore rotor angle detector and control unit just can direct connections by bunch, therefore, can also omit the bunch that is used for the rotor angle signal is sent to control unit, miniaturization and and electric power-assisted steering apparatus more cheaply can be provided.

And, the described electric power-assisted steering apparatus in the present invention the 32nd aspect, the described invention in the 31st aspect according to the present invention, it is characterized in that, above-mentioned electro-motor has connecting portion, this connecting portion cooperates with the motor attachment face of above-mentioned reducing gearbox, and pass through bolted, above-mentioned rotor angle detector is housed in this connecting portion, and, the electric contact of above-mentioned electro-motor is with respect to forming highlightedly at least one side of above-mentioned reducing gearbox side end face to vertical direction and horizontal direction, and the electric contact of above-mentioned rotor angle detector forms highlightedly with respect at least one side of above-mentioned reducing gearbox side end face to vertical direction and horizontal direction.

Aspect this present invention the 32nd in the described invention, electro-motor be connected electric contact on the motor coil, outstanding from the end face of connecting portion at least one side of vertical direction and horizontal direction, its easily with the direct connection that is assembled in the electric connection terminal of the control unit on the reducing gearbox, can make from the output stage of control unit very short to the distribution of motor coil, therefore, can reduce the distribution loss, high efficiency electric power-assisted steering apparatus can be provided.

In addition, because the electric contact of rotor angle detector is with respect to the reducing gearbox side end face of motor flange, at least one side to vertical direction and horizontal direction forms highlightedly, therefore, become easy with the direct connection of the electric contact that is assembled in the control unit on the reducing gearbox, do not use bunch just the necessary rotor angle signal of the commutation of brushless motor can be delivered to control unit, therefore, can provide electric power-assisted steering apparatus cheaply.

In addition, the described electric power-assisted steering apparatus in the present invention the 33rd aspect, each described invention according to the present invention in the 30th to the 32nd aspect, it is characterized in that, above-mentioned torque sensor has the outside electric contact that connects usefulness, the electric contact that this outside connects usefulness is connected on the either party in moment of torsion detecting element and the signal processing circuit thereof, above-mentioned control unit has the electric contact bonded assembly electric contact with above-mentioned torque sensor, under the state that above-mentioned torque sensor and above-mentioned control unit is assembled on the above-mentioned reducing gearbox, the electric contact of this torque sensor and the electric contact of this control unit are configured in the position that is connected to each other directly.

Aspect this present invention the 33rd in the described invention, owing to can will be connected in electric contact on the torque sensor and the control unit and electric contact bonded assembly electric contact direct connection torque sensor, therefore, just can will not couple together between torque sensor and the control unit by bunch, can omit the bunch that is used for steering torque is delivered to control unit, and more small-sized light weight and electric power-assisted steering apparatus cheaply can be provided.

And, the described electric power-assisted steering apparatus in the present invention the 34th aspect, the described invention in the 33rd aspect according to the present invention, it is characterized in that, above-mentioned torque sensor forms to vertical direction highlightedly with respect to the attachment face of above-mentioned control unit under above-mentioned electric contact is assembled in state on the above-mentioned reducing gearbox.

Aspect this present invention the 34th in the described invention, under the electric contact of torque sensor is assembled in state on the reducing gearbox, this electric contact is outstanding to vertical direction from the control unit attachment face of reducing gearbox, therefore, become easy with the direct connection of the electric connection terminal that is assembled into the control unit on the reducing gearbox, do not use bunch just can with the control of electric power-assisted steering apparatus indispensable steering torque be delivered to control unit, can make the electric power-assisted steering apparatus miniaturization.

In addition, the described electric power-assisted steering apparatus in the present invention the 35th aspect, each described invention according to the present invention in the 30th to the 34th aspect, it is characterized in that, above-mentioned speed reduction gearing is made of worm reducer, and the above-mentioned control unit attachment face of above-mentioned reducing gearbox is the plane with respect to the axial vertical direction of worm gear.

Aspect this present invention the 35th in the described invention, because the control unit attachment face is the plane with respect to the axial vertical direction of worm gear, therefore, can be with across the steering torque sensor of the steering handwheel side that is built in worm gear and the form that is configured in the electro-motor of worm shaft end, the configuration control unit, it is easy that the direct connection of the end of torque sensor and control unit becomes, do not use bunch just can with the control of electric power-assisted steering apparatus indispensable steering torque be delivered to control unit, can make the electric power-assisted steering apparatus miniaturization.

And, the described electric power-assisted steering apparatus in the present invention the 36th aspect, each the described invention according to the present invention in the 30th to the 32nd aspect is characterized in that, shape on the Width of above-mentioned control unit forms axisymmetrically with respect to the axle center of above-mentioned electro-motor.

Aspect this present invention the 36th in the described invention, because the axle center of the relative electro-motor of Width shape of control unit forms rotational symmetry, therefore, even at corresponding right jiggering and LHS car and changed under the situation of installation direction of electro-motor, setting height(from bottom) can not create a difference yet, therefore, do not need to change electro-motor and control unit, electric power-assisted steering apparatus cheaply can be provided.

And, the described electric power-assisted steering apparatus in the present invention the 37th aspect, each described invention according to the present invention in the 30th to the 34th aspect, it is characterized in that, the electric contact at above-mentioned electro-motor of above-mentioned control unit is made of the screw thread fixed terminal, and this screw thread fixed terminal is electrically connected with the electric contact of this electro-motor contiguously by screw shaft power.

Aspect this present invention the 37th in the described invention, control unit uses the screw thread fixed terminal that is electrically connected contiguously by screw shaft power and motor-side electric contact, be used as electric contact bonded assembly electric contact with electro-motor, therefore, can firmly and reliably be electrically connected, the distribution loss can be reduced, and the fluctuation of contact resistance can be suppressed.

And, the described electric power-assisted steering apparatus in the present invention the 38th aspect, each described invention according to the present invention in the 30th to the 34th aspect, it is characterized in that, the electric contact at above-mentioned electro-motor of above-mentioned control unit is made of the spring contact terminal, this spring contact terminal is electrically connected with the electric contact of this electro-motor contiguously by spring pressure, under the state that above-mentioned control unit is assembled on the above-mentioned reducing gearbox, the insertion mouth of above-mentioned spring contact terminal is towards the motor attachment face opening of this reducing gearbox.

Aspect this present invention the 38th in the described invention, because control unit uses the spring contact terminal that is electrically connected contiguously by the spring pressure and the electric contact of electro-motor, be used as electric contact bonded assembly electric contact with electro-motor, it inserts mouthful under control unit is assembled in state on the reducing gearbox, motor attachment face opening on reducing gearbox, therefore, when electro-motor being installed on the motor attachment face, only just can be electrically connected by the electric contact that inserts electro-motor, can reduce the distribution loss, and can reduce work hours, in addition owing to do not carry out mechanical fixation between two electric contacts, therefore, can discharge because of assembly error, each parts precision and linear expansion factor difference etc. and the stress that produces.

In addition, the described electric power-assisted steering apparatus in the present invention the 39th aspect, each described invention according to the present invention in the 30th to the 34th aspect, it is characterized in that, the electric contact at above-mentioned electro-motor of above-mentioned control unit is undertaken and being electrically connected of the electric contact of this electro-motor by in welding or the soldering any.

Aspect this present invention the 39th in the described invention because between the electric contact of control unit and electro-motor, by weld or soldering in any connect, therefore, can obtain firm and the failure-free electrical connection, can reduce the distribution loss, and can suppress the fluctuation of contact resistance.

And, the described electric power-assisted steering apparatus in the present invention the 40th aspect, the described invention in the 31st or the 32nd aspect according to the present invention, it is characterized in that, the electric contact at above-mentioned rotor angle detector of above-mentioned control unit is made of the spring contact terminal, and this spring contact terminal is electrically connected contiguously by the electric contact of spring pressure with this rotor angle detector.

Aspect this present invention the 40th in the described invention, control unit uses the spring contact terminal that is electrically connected contiguously by the spring pressure and the electric contact of the rotor angle detector of electro-motor, be used as electric contact bonded assembly electric contact with the rotor angle detector, it inserts mouthful under control unit is assembled in state on the reducing gearbox, motor attachment face opening on reducing gearbox, therefore, when electro-motor is assembled into the motor attachment face, only be inserted in the spring contact terminal by electric contact with the rotor angle detector, just can obtain to be electrically connected, can reduce and connect man-hour.

In addition, the described electric power-assisted steering apparatus in the present invention the 41st aspect, the described invention in the 31st or the 32nd aspect according to the present invention, it is characterized in that, the electric contact at above-mentioned rotor angle detector of above-mentioned control unit, by in welding or the soldering any, carry out and being electrically connected of the electric contact of this rotor angle detector.

Aspect this present invention the 41st, in the described invention,, therefore, can prevent the bad contact of contact, improve the reliability of contact because the electric contact of control unit and rotor angle detector is undertaken firmly and the failure-free electrical connection by welding or soldering.

And, the described electric power-assisted steering apparatus in the present invention the 42nd aspect, the described invention in the 33rd or the 34th aspect according to the present invention, it is characterized in that, the electric contact at above-mentioned torque sensor of above-mentioned control unit is made of the spring contact terminal, and this spring contact terminal is electrically connected with the electric contact of this torque sensor contiguously by spring pressure.

Aspect this present invention the 42nd in the described invention, control unit uses the spring contact terminal that is electrically connected contiguously by the spring pressure and the electric contact of torque sensor, be used as electric contact bonded assembly electric contact with torque sensor, it inserts mouthful under control unit is assembled in state on the reducing gearbox, control unit attachment face opening in the reducing gear parts, therefore, when being assembled into control unit on the reduction gear unit, only be inserted in the spring contact terminal by electric contact with torque sensor, just can be electrically connected, can reduce and connect man-hour.

In addition, the described electric power-assisted steering apparatus in the present invention the 43rd aspect, the described invention in the 33rd or the 34th aspect according to the present invention, it is characterized in that, the electric contact at above-mentioned torque sensor of above-mentioned control unit, by in welding or the soldering any, carry out and being electrically connected of the electric contact of this torque sensor.

Aspect this present invention the 43rd, in the described invention,, therefore, can prevent the bad contact of contact, improve reliability because the electric connection terminal of control unit and torque sensor is undertaken firmly and the failure-free electrical connection by welding or soldering.

And, the described electric power-assisted steering apparatus in the present invention the 44th aspect, each the described invention according to the present invention in the 30th to the 43rd aspect is characterized in that, the electric contact at above-mentioned electro-motor of above-mentioned control unit is provided with and carries out waterproof and antisoiling sealing mechanism.

Aspect this present invention the 44th in the described invention, owing to be provided with at the junction surface of the electric contact of control unit and electro-motor and be used for waterproof and antisoiling sealing mechanism, therefore, not only can be applied to be arranged on the post assist type electric servo steering device in the compartment, and can be applied in such being configured in the interior electric power-assisted steering apparatus of machinery space of electric power-assisted steering apparatus of miniature gears assist type or rack assist type.

In addition, the described electric power-assisted steering apparatus in the present invention the 45th aspect, each the described invention according to the present invention in the 30th to the 44th aspect is characterized in that, the electric contact at above-mentioned rotor angle detector of above-mentioned control unit is provided with and carries out waterproof and antisoiling sealing mechanism.

Aspect this present invention the 45th in the described invention, because junction surface at the electric contact of control unit and rotor angle detector, be provided with and be used for waterproof and antisoiling sealing mechanism, therefore not only can be applied to be arranged on the post assist type electric servo steering device in the compartment, and can be applied in such being configured in the interior electric power-assisted steering apparatus of machinery space of electric power-assisted steering apparatus of miniature gears assist type or rack assist type.

And, the described electric power-assisted steering apparatus in the present invention the 46th aspect, each the described invention according to the present invention in the 30th to the 45th aspect is characterized in that, the electric contact at above-mentioned torque sensor of above-mentioned control unit is provided with and carries out waterproof and antisoiling sealing mechanism.

Aspect this present invention the 46th in the described invention, because junction surface at the electric contact of control unit and torque detecting apparatus, be provided with and be used for waterproof and antisoiling sealing mechanism, therefore, not only can be applied to be arranged on the post assist type electric servo steering device in the compartment, and can be applied in such being configured in the interior electric power-assisted steering apparatus of machinery space of electric power-assisted steering apparatus of miniature gears assist type or rack assist type.

In addition, the described electric power-assisted steering apparatus in the present invention the 47th aspect, each described invention according to the present invention in the 30th to the 46th aspect, it is characterized in that, above-mentioned speed reduction gearing is made of worm reducer, the position of above-mentioned worm shaft is housed on above-mentioned reducing gearbox, is formed with the control unit attachment face that above-mentioned control unit is installed.

Aspect this present invention the 47th in the described invention, because above-mentioned speed reduction gearing is made of worm reducer, the position of worm shaft is housed on above-mentioned reducing gearbox, be formed with the control unit attachment face that above-mentioned control unit is installed, therefore, assemble with the axial consistent direction of worm shaft by length direction, can not make control unit carry out layout highlightedly with control unit.In addition, can obtain and the cooresponding sufficient contact surface of the seating plane of control unit, and, improve with the adaptation of control unit, the heat of control unit can be delivered to reducing gearbox efficiently thus, omission is arranged on the radiating fin in the control unit, can make the electric power-assisted steering apparatus miniaturization.

And, the described electric power-assisted steering apparatus in the present invention the 48th aspect, the described invention in the 32nd aspect according to the present invention, it is characterized in that, above-mentioned speed reduction gearing is made of worm reducer, above-mentioned worm shaft combines with the output shaft spline of above-mentioned electro-motor, and it is long from the outstanding length of above-mentioned mounting flange end face than the electric contact of the electric contact of above-mentioned electro-motor and rotor angle detector in conjunction with length setting.

Aspect this present invention the 48th in the described invention, the joint of the output shaft of worm shaft and electro-motor is a spline, its length of fit is longer from the outstanding length of mounting flange end face than the electric contact of the electric contact of electro-motor and rotor angle detector, therefore, under the state that cooperates very shallowly between the spline, make the electro-motor rotation, can carry out the electric contact of rotor angle detector and electro-motor, contraposition with the electric contact of control unit, as coupler, use the spline combination, can omit the bunch that is used to transmit the bunch of rotor angle signal and is used for the motor energising simultaneously.

In addition, the assemble method of the described electric power-assisted steering apparatus in the present invention the 49th aspect is the assemble method of electric power-assisted steering apparatus, this electric power-assisted steering apparatus is assembled with on reducing gearbox: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; Torque sensor, it is used to detect above-mentioned steering torque; Electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in the above-mentioned reducing gearbox with power steering; And control unit, it comes the above-mentioned electro-motor of drive controlling according to by the detected steering torque of above-mentioned torque sensor, it is characterized in that,

Constitute above-mentioned torque sensor by the moment of torsion detecting element, dress signal processing circuit in above-mentioned control unit, this signal processing circuit is to carrying out signal conditioning by the detected steering torque detecting signal of above-mentioned moment of torsion detecting element, to install in the above-mentioned torque sensor in the above-mentioned reducing gearbox, then, be equipped with on the above-mentioned reducing gearbox of above-mentioned torque sensor in above-mentioned control unit is assembled into, carry out the electrical connection of above-mentioned moment of torsion detecting element and above-mentioned control unit, next, above-mentioned electro-motor is assembled on the reducing gearbox, and carries out the electrical connection of control unit and electro-motor.

Aspect this present invention the 49th in the described invention, owing to only constitute torque sensor by the moment of torsion detecting element, be contained in the control unit in its signal processing circuit quilt, in being assembled in, control unit is equipped with under the state on the reducing gearbox of moment of torsion detecting element, carry out being electrically connected between control unit and moment of torsion detecting element, then electro-motor is assembled on the reducing gearbox, therefore, stage on the reducing gearbox of moment of torsion detecting element is housed in control unit is assembled into, can carries out the correction of signal processing circuit.Therefore, both can omit bunch, again needn't with control unit signalization treatment circuit separately, and can not be subjected to the influence ground of electro-motor to carry out the correction of signal processing circuit, can cut down components number and can not reduce the precision of torque sensor.

And, the assemble method of the described electric power-assisted steering apparatus in the present invention the 50th aspect is the assemble method of electric power-assisted steering apparatus, and this electric power-assisted steering apparatus is assembled with on reducing gearbox: Steering gear, steering shaft is housed in it, and steering torque is passed to this steering shaft; Torque sensor, it is used to detect above-mentioned steering torque; Electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in the above-mentioned reducing gearbox with power steering; And control unit, it comes the above-mentioned electro-motor of drive controlling according to by the detected steering torque of above-mentioned torque sensor, it is characterized in that,

Constitute above-mentioned torque sensor by the moment of torsion detecting element and to the signal processing circuit that its steering torque detecting signal carries out signal conditioning, above-mentioned moment of torsion detecting element and above-mentioned signal processing circuit are assembled in the above-mentioned reducing gearbox, then, above-mentioned electro-motor is assembled on the above-mentioned reducing gearbox, next, above-mentioned control unit is assembled on the above-mentioned reducing gearbox, and carry out being electrically connected between control unit and the moment of torsion detecting element, and being electrically connected between control unit and the electro-motor.

Aspect this present invention the 50th in the described invention, owing to come the correction torque sensor by moment of torsion detecting element and signal processing circuit, this signal processing circuit and control unit dispose separately, therefore, can under the state of reducing gearbox monomer, proofread and correct the signal processing circuit in the torque sensor.And, electro-motor is assembled on the reducing gearbox of the correction of having finished signal processing circuit, then, control unit is assembled on the reducing gearbox, under this state, carries out being electrically connected between control unit and the moment of torsion detecting element, and being electrically connected between control unit and the electro-motor, therefore, assembling becomes easily, can simplify assembling procedure and can not reduce the precision of torque sensor.

According to the present invention, electro-motor and control unit are set up in parallel on reducing gearbox, and, electro-motor with control unit near and opposed position on the outstanding motor-side connecting portion that forms, on and the opposed position approaching of control unit, form the cell side connecting portion that contacts with motor-side connecting portion face with electro-motor, therefore have following effect: can by near and the motor-side connecting portion of face contact and cell side connecting portion carry out connection between electro-motor and the control unit, can make electrical connection length between the two the shortest, make the wiring resistance minimum, and can prevent sneaking into of electrical noise reliably, and do not need to form the big splicing ear of rigidity, assembleability is improved.

In addition, owing to need the motor wire harness be set between electro-motor and control unit, therefore, the noise disappearance from the radiation of motor wire harness can access this effect that influences that can alleviate radio noise.

And, by making the motor-side connecting portion outstanding towards the direction of quadrature axial with it from electro-motor, when being installed to electro-motor on the reducing gearbox, can prevent from reliably to damage this effect of cell side connecting portion while electro-motor being rotated under the situation of installing, can accessing because of the motor-side connecting portion.

And, the attachment face at above-mentioned reducing gearbox that is configured to electro-motor by the contact surface with motor-side connecting portion and cell side connecting portion is same plane, when being installed to electro-motor on the reducing gearbox, carrying out under the stack-mounted situation while electro-motor is rotated, can obtain to prevent reliably that the protrusion such as mounting flange of electro-motor and the connecting portion of control unit side from interfering this effect.

In addition, the contact surface by making motor-side connecting portion and cell side connecting portion electro-motor axially on, can obtain to reduce the height of contact surface, and can guarantee this effect of enough area of contact.

And the distance of establishing from the shell-side end face that is formed at the motor flange on the electro-motor to the front end of motor-side splicing ear is L4; If the distance from the motor-side end face of the motor mounting flange that is formed at gear hub to the motor-side end face of the worm shaft of turbine mechanism is L5; If the distance from the motor-side end face of motor mounting flange to the front end of control unit side splicing ear is L6; Make distance L 4, distance L 5 and distance L 6 and, less than distance L 7 from the shell-side end face of motor flange to the front end face of the output shaft of electro-motor, thus, with before the worm shaft of Worm gear mechanism cooperates, the motor-side splicing ear does not overlap with control unit side splicing ear at the output shaft of electro-motor.Therefore, can easily carry out the phase matched of the worm shaft of the output shaft of electro-motor and Worm gear mechanism.

In addition, at least one side who makes motor-side splicing ear and substrate-side splicing ear is a flexible structure, making the opposing party is rigid construction, by making a side elastic deformation takes place with both electrical connections, therefore, do not need motor-side splicing ear and substrate-side splicing ear are configured on the high-precision position, do not need to make motor-side splicing ear and substrate-side splicing ear both to be flexible structure yet, therefore, can obtain to realize this effect of reduction of manufacturing cost.

And, according to the present invention, because electro-motor and control unit are assembled on the reducing gearbox, therefore can be big with directly be delivered to heat absorption capacity efficiently by the heating that control unit produced, and on the also big reducing gearbox of face area, can reduce or omit the radiating fin of control unit as much as possible, can realize the miniaturization and of control unit, and, owing to use brushless motor as electro-motor, therefore, the loss that is not caused by the contact resistance of brush can be omitted the bunch that is used for the motor energising, can produce the big augmented thrust that turns to, can access and electric power-assisted steering apparatus can be applied to this effect on the Oversize vehicle.In addition, being applied under the situation that does not need big medium-sized, the compact car that turns to augmented thrust,, therefore, also can access and to make electro-motor and control unit than present situation this effect of miniaturization more because loss is little.And, except can omitting the motor wire harness between control unit and the electro-motor, can also omit rotor angle detectors such as the resolver that is installed on the electro-motor and be installed in steering torque sensor on the reducing gearbox and the bunch between the control unit, more small-sized light weight and electric power-assisted steering apparatus cheaply can be provided.

Description of drawings

Fig. 1 is the block diagram of the 1st embodiment of expression electric power-assisted steering apparatus of the present invention.

Fig. 2 is the front elevation of expression electric power-assisted steering apparatus of the present invention.

Fig. 3 is the left side view of Fig. 2.

Fig. 4 is the birds-eye view of Fig. 2.

Fig. 5 is the exploded perspective view of main portion of the present invention.

Fig. 6 is the exploded perspective view from the direction observed of the present invention main portion opposite with Fig. 5.

Fig. 7 is the longitudinal section that amplifies the main portion of expression reducing gearbox position.

Fig. 8 is the front elevation of the bus structure of expression electro-motor.

Fig. 9 is the block diagram of the relation of expression reducing gearbox and control basal plate.

Figure 10 is the block diagram that expression runs through the external connection terminals of the torque sensor in the reducing gearbox state that is inserted into control basal plate.

Figure 11 is the figure of the annexation of expression electro-motor and control unit, (a) is block diagram, (b) is the enlarged drawing of main portion.

The block diagram of the electric power-assisted steering apparatus when Figure 12 is the expression crumple.

The left side view of the electric power-assisted steering apparatus when Figure 13 is the expression crumple.

The birds-eye view of the electric power-assisted steering apparatus when Figure 14 is the expression crumple.

Figure 15 is the block diagram of variation of the splicing ear of expression electro-motor.

Figure 16 be expression with the motor-side connecting portion of fastener with electro-motor, the figure of the state that couples together with the cell side connecting portion of control unit.

The figure of Figure 17 state that to be expression weld the cell side connecting portion of the motor-side connecting portion of electro-motor and control unit.

The figure of Figure 18 state that to be expression couple together the cell side connecting portion of the motor-side connecting portion of electro-motor and control unit with gynetype terminal and male type terminal.

Figure 19 is that expression makes the splicing ear of electro-motor form the lateral plan of the embodiment consistent with attachment face.

Figure 20 is illustrated in the car of left and right directions dish, makes the figure of the unitized embodiment of electro-motor.

Figure 21 is illustrated in the figure that makes unitized another embodiment of electro-motor in the left and right directions jiggering.

Figure 22 is the birds-eye view of the 2nd embodiment of expression electric power-assisted steering apparatus of the present invention.

Figure 23 is the electro-motor of expression in the 2nd embodiment and the instruction diagram of the installation relation of control unit in reducing gearbox, (a) be the main portion birds-eye view that the worm screw incorporating section of reducing gearbox is cut open, (b) being the exploded drawings of above-mentioned main portion, (c) is the block diagram of the relation of expression splicing ear and terminal base.

Figure 24 is the instruction diagram of the 3rd embodiment of expression electric power-assisted steering apparatus of the present invention; (a) be the instruction diagram of expression electro-motor and the control unit installation relation in reducing gearbox; (a) be the main portion birds-eye view that the worm screw incorporating section of reducing gearbox of having pulled down the state of protective case is cut open, (c) be the exploded drawings of above-mentioned main portion.

Figure 25 is the block diagram of Connection Step of the cell side connecting portion of the motor-side connecting portion of the electro-motor of expression in the 3rd embodiment and control unit.

Figure 26 is the block diagram of the part of the described electric power-assisted steering apparatus of exploded representation the 4th embodiment of the present invention.

Figure 27 is the in-to-in cutaway view of expression gear hub shown in Figure 26 (gear housing).

Figure 28 is the figure of the main portion of the described electric power-assisted steering apparatus of expression the 4th embodiment of the present invention.

Figure 29 is the figure that is used to illustrate the effect of the described electric power-assisted steering apparatus of the 4th embodiment of the present invention.

Figure 30 is the front elevation of the inner structure of the expression electro-motor that constitutes the electric power-assisted steering apparatus in the 5th embodiment of the present invention.

Figure 31 is the figure of connection structure of the terminal base of the splicing ear of the electro-motor of expression in the 5th embodiment and control unit.

Figure 32 is the figure of other shape of the outstanding splicing ear of the electro-motor of expression from the 5th embodiment.

Figure 33 is the block diagram of expression the 6th embodiment of the present invention.

Figure 34 is the exploded perspective view of Figure 33.

Figure 35 is the block diagram that the state behind the electro-motor is pulled down in expression.

Figure 36 is the longitudinal section of reducing gearbox.

Figure 37 is the block diagram of expression electro-motor.

Figure 38 is the exploded perspective view of electro-motor.

Figure 39 is the block diagram of expression control unit, (a) is the block diagram of face side, (b) is the block diagram of rear side.

Figure 40 is the exploded perspective view before the electro-motor shown in assembling the 7th embodiment of the present invention.

The specific embodiment

Below, with reference to the accompanying drawings embodiments of the present invention are described.

To be expression be applied in the block diagram of an example of the situation of right jiggering with the 1st embodiment of the present invention to Fig. 1, and Fig. 2 is a front elevation, and Fig. 3 is a left side view, and Fig. 4 is a birds-eye view, and Fig. 5 and Fig. 6 are the exploded perspective views of main portion.

In Fig. 1, the 1st, the electric power-assisted steering apparatus of pillar, steering shaft 2 has the 2a of steering-wheel placing portion of installation steering handwheel (not shown), steering shaft 2 can rotate freely and be loaded in the ground in the Steering gear 3, on Steering gear 3, be connected with reducing gearbox 4, on this reducing gearbox 4, be equipped with the electro-motor 5 that constitutes by the brush motor, electro-motor 5 axially along extending with the direction of the axial quadrature of Steering gear 3.

Here, Steering gear 3 is the double-sleeve structure of pipe 3a in adopting and outer tube 3b, and the impact energy when absorbing crumple at the connecting portion place with reducing gearbox 4 is guaranteed the crumple stroke of being scheduled to.In addition, the outer tube 3b of Steering gear 3 and reducing gearbox 4 are installed in body side by upper mounting bracket 6 and bottom installation bracket 7.

Bottom installation bracket 7 is by forming with lower member: board 7a is installed, and it is installed on the body-side member (not shown); With a pair of supporting board 7b, they extend in parallel in the predetermined compartment of terrain of lower surface maintenance of this installation board 7a.In addition, the front end of supporting board 7b by pivot 7c, is connected on the support 4b that is integrally formed at lid 4a free to rotately, this lid 4a be provided in reducing gearbox 4 lower end side, be the vehicle body front side.

In addition, upper mounting bracket 6 has: board 6a is installed, and it is installed on the body-side member (not shown); Square box shape support 6b, it is formed on this installation board 6a; And leaning device 6c, it supports the outer tube 3b that is formed on the Steering gear 3 on this square box shape support 6b.

Here, board 6a is installed by constituting as the lower part: about a pair of chuck (capsule) 6d of one-tenth, they are installed on the body-side member (not shown); With slip board 6f, it is fixed on these chucks 6d by the 6e of resin injection portion, board 6a is installed to constitute: the impulsive force that effect makes Steering gear 3 move to vehicle body the place ahead on Steering gear 3 when collision, thereby, slip board 6f slides to vehicle body the place ahead with respect to chuck 6d, the 6e of resin injection portion is sheared, and this shearing load just becomes crumple and begins load.

In addition, rotating by the tilting bar 6g that makes leaning device 6c, remove bearing state, can be the center with the pivot 7c of bottom installation bracket 7 thus, up and down Steering gear 3 is carried out the obliquity adjustment.

And as shown in Figure 7, steering shaft 2 is by constituting as the lower part: input shaft 2b, and its upper end is connected on the steering handwheel (not shown); With output shaft 2d, it is connected with the lower end of this input shaft 2b by torsion bar 2c, and covers torsion bar 2c.

In addition, as Fig. 5～shown in Figure 7, casting forming forms reducing gearbox 4 by for example carrying out in material, for example aluminium, aluminum alloy, magnesium and the magnesium alloy with high thermal conductivity any.This reducing gearbox 4 has: worm screw incorporating section 12, and it takes in the output shaft 5a bonded assembly worm screw 11 with electro-motor 5; Worm gear incorporating section 14, its downside in this worm screw incorporating section 12 have the center shaft with the orthogonality of center shaft of worm screw incorporating section 12, and take in and worm screw 11 ingear worm gears 13; Torque sensor incorporating section 16, its one and be connected the rear side of this worm gear incorporating section 14 coaxially is used to take in torque sensor 15; Motor installation portion 17, the open end face that it is formed at worm screw incorporating section 12 is used to install electro-motor 5; Post installation portion 18, the aft end face that it is formed at torque sensor incorporating section 16 is used to install the mounting flange 3c that is formed on these Steering gear 3 leading sections; And control unit installation portion 20, it is across the part of worm screw incorporating section 12 and worm gear incorporating section 14, is formed in the central axis plane orthogonal with worm gear incorporating section 14 and torque sensor incorporating section 16, is used for installation and control unit 19.And, under the state of mounting flange 3c that makes Steering gear 3 and post installation portion 18 butts,, reducing gearbox 4 is fixed on the Steering gear 3 by bolt 18a.

At this, as shown in Figure 7, torque sensor 15 constitutes: by magnetic the input shaft 2b of steering shaft 2 and the twisting states between the output shaft 2d are detected, utilize a pair of magnetic test coil 15a and 15b to detect the steering torque that is delivered to steering shaft, spiral head and spiral tail at these a pair of magnetic test coil 15a and 15b are connected with external connection terminals 15c respectively, 15d and 15e, 15f, described external connection terminals 15c, 15d and 15e, 15f is along outstanding to the outside abreast with the direction of the orthogonality of center shaft of Steering gear 3, the protrusion of these external connection terminals 15c～15f the central axes of central portion and Steering gear 3 bending and form L word shape.

And, in electro-motor 5, near the position of an one 5b of mounting flange portion, be installed on the control unit installation portion 20 control unit 19 near and opposed position on, outstanding splicing ear 5c and the 5d that is formed with as the motor connecting portion, this splicing ear 5c and 5d and bus (bus-bar) 5i and the 5j that built-in brush is carried out distribution described later form as one, and towards with the axis direction of electro-motor 5 rectangular vehicle body rear and also with the center shaft almost parallel of Steering gear 3.At the leading section of these splicing ears 5c and 5d, be equipped with and run through the slotted hole 5e that inserts bolt of rear end plate.At this moment, as shown in Figure 3, when observing Steering gear 3 from the side, the line segment L1 that connects a pair of mounting flange 5b of portion, with the angle θ that extending direction became of the L2 of Central Line between splicing ear 5c and 5d be acute angle (for example, 60 °), the direction parallel with Steering gear 3 and with the direction of its quadrature on, the outstanding length of the 5b of mounting flange portion is suppressed and miniaturization.

At this, as shown in Figure 8, splicing ear 5c and 5d are provided in the plastic brush supporting mass 5f respectively insulated from each otherly, brush supporting mass 5f has armature in bottom center and runs through patchhole, splicing ear 5c and 5d are formed on the mutual opposed end of circular- arc bus 5i and 5j, and described bus 5i and 5j are connected on 2 groups of brush 5g, 5h severally.And electro-motor 5 is by following installation: the 5b of its mounting flange portion is connected on the motor installation portion 17 of reducing gearbox 4, and 5a is connected on the worm screw 11 with its output shaft, and splicing ear 5c and 5d are prolonged to the vehicle body rear.

And, as reference Fig. 9 as can be known, about being formed on the control unit installation portion 20 on the reducing gearbox 4, the upper side of the worm gear incorporating section 14 by worm screw incorporating section 12 and downside thereof forms smooth attachment face 20a, by smooth attachment face 20a and be formed on torque sensor incorporating section 16 upper surfaces, with the tabular surface 20b of smooth attachment face 20a quadrature, observe from left surface, control unit installation portion 20 forms L word shape.In addition, on the aft end face of motor installation portion 17, also be formed with the narrow framework attachment face 20c of width, this framework attachment face 20c is parallel with smooth attachment face 20a, and compares with this smooth attachment face and to be positioned at the rear side position.And the central portion of left and right directions from the torque sensor incorporating section 16, tabular surface 20b is extruded with the external connection terminals 15c～15f of torque sensor 15.

As Fig. 5, Fig. 6 and shown in Figure 10, be installed in the control unit 19 on this control unit installation portion 20, by following component set-up: the metal power substrate 23 that thermal conduction rating is high, it directly is fixed on the smooth attachment face 20a across thermal grease, be used to install electro-motor 5 is carried out H bridge circuit drive controlling, that be made of field effect transister equipower on-off element, or the discrete elements such as pulse width modulation circuit that the power switch component of this H bridge circuit is driven; The synthetic resin system framework 24 of oblong frame shape, it is around this power substrate 23; Control basal plate 25, be equipped with through hole 25a～25d on it, external connection terminals 15c～the 15f that is installed in the torque sensor 15 in these synthetic resin system framework 24 fronts directly runs through and is inserted among through hole 25a～25d, and, micro-control unit (MCU) and external equipment thereof are installed on the control basal plate 25, described micro-control unit is according to from the moment of torsion detected value of torque sensor 15 or from the speed of a motor vehicle detected value of not shown car speed sensor, calculate and turn to the auxiliary current command value, turn to auxiliary current command value and the detected value of exporting to the motor current of electro-motor 5 to carry out Current Feedback Control according to this, calculate voltage instruction value, thus the power steering that is produced by electro-motor 5 is controlled to the pulse width modulation circuit of power substrate 23; Lid 26, it covers power substrate 23, synthetic resin system framework 24 and control basal plate 25.

At this, synthetic resin system framework 24 is by constituting integratedly as the lower part: the chassis body 24a of oblong frame shape; Board 24b is installed, it is outstanding be formed on this chassis body 24a left end with splicing ear 5c electro-motor 5 and 5d near and opposed position, and be fixed on the framework attachment face 20c of reducing gearbox 4; As the terminal base 24c of cell side connecting portion, it protrudes L word shape from this installation board 24b, and is electrically connected contiguously with the splicing ear 5c and the 5d face of electro-motor 5; Power connector 24d, it is provided in the middle position at chassis body 24a right-hand member place, is connected with battery (not shown); And signal connector 24e, the middle position that it is provided in chassis body 24a right-hand member place, carry out and the control convenience of each one of vehicle body between the transmitting-receiving of data, be connected with networks such as CAN.At this, power connector 24d and signal connector 24e are formed with the adaptor union that continues in the right-hand member side respectively and insert opening, so that carry out from the right flank side of vehicle body with the direction of insertion of the exterior adaptor union that continues of their bonded assemblys.

And, about control unit 19 with said structure, at first, the installation site of the power substrate 23 on the smooth attachment face 20a of the control unit installation portion 20 of reducing gearbox 4, the coating thermal grease, then, power substrate 23 is placed on the thermal grease, be fixed on the smooth attachment face 20a with Screw, then, synthetic resin system framework 24 be placed on smooth attachment face 20a and the framework attachment face 20c in the mode around power substrate 23.Then, with the installation board 24b of synthetic resin system framework 24, similarly be fixed on the framework attachment face 20c of reducing gearbox 4 with Screw.After this or before, run through among the through hole 25a～25d that is inserted into control basal plate 25 at external connection terminals 15c～15f torque sensor 15, then control basal plate 25 usefulness Screws are fixed to the face side of synthetic resin system framework 24, at last, after external connection terminals 15c～15f and through hole 25a～25d soldering are got up, at last lid 26 is installed on the smooth attachment face 20a.

Then, assembling Steering gear 3, steering shaft 2, worm screw 11 and worm gear 13, assemble electro-motor 5 at last, splicing ear 5c and 5d side from electro-motor 5, to pass slotted hole 5e and screw on terminal base 24c, thus as the fixedly Screw 5o of fastener, splicing ear 5c and 5d are electrically connected with terminal base 24c, and the mounting terminal lid 27 then.

Like this, the position of the smooth attachment face 20a of the thickness of control unit 19 and control unit installation portion 20 is configured to: under the state on the control unit installation portion 20 that control unit 19 is assemblied in reducing gearbox 4, the aft end face position of the lid 26 of control unit 19 and the rearmost end position of reducing gearbox 4 are positioned at the position than the close front side of head of bolt 18a, described bolt 18a is used for fixing the mounting flange 3c of Steering gear 3, stopper section when Steering gear when the mounting flange 3c of described Steering gear 3 becomes crumple shrinks, control unit 19 is assembled in following position: the moving-member when control unit 19 can be with crumple when crumple described later interferes.

In addition, control unit 19 with electro-motor 5 opposite sides, it is the right flank side of vehicle, be equipped with power connector 24d and signal connector 24e, electro-motor 5, control unit 19, and power connector 24d and signal connector 24e configuration in-line, the battery side adaptor union is connected with signal connector 24e with power connector 24d easily with the network side adaptor union thus, and, about power connector 24d, usually be in position near earth point, described earth point is arranged on the position, the cabin side left and right sides of the engine room of vehicle, can shorten the length of the grounding jumper between power connector 24d and the earth point.And the closure of power connector 24d and signal connector 24e and double-type adaptor union is horizontal direction, can prevent the intrusion of water droplet or dust.

Below, the action of above-mentioned the 1st embodiment is described.

At first, when assembling electric power-assisted steering apparatus 1, in the torque sensor incorporating section 16 of reducing gearbox 4, fixed configurations torque sensor 15 makes the peripheral part of the front end edge Steering gear 3 of its external connection terminals 15c～15f prolong to the vehicle body rear.

Then, installation and control unit 19 on the control unit installation portion 20 of reducing gearbox 4.About the installation of this control unit 19, at first, on smooth attachment face 20a, apply thermal grease, then, on thermal grease, place power substrate 23, and be fixed on the smooth attachment face 20a with Screw.Under this state, synthetic resin system framework 24 to be placed on the smooth attachment face 20a around the mode of power substrate 23, to be made it that board 24b is installed and contacts with the framework attachment face 20c of reducing gearbox 4 and fix with Screw.Then, in the front of synthetic resin system framework 24, be vehicle body rear side fixed control substrate 25, external connection terminals 15c～the 15f of torque sensor 15 is run through among the through hole 25a～25d that is inserted into control basal plate 25, and after the external connection terminals 15c～15f soldering together with through hole 25a～25d and torque sensor 15, lid 26 is installed, is constituted control unit 19 thus.

Then, on reducing gearbox 4, install after steering shaft 2, Steering gear 3, worm screw 11 and the worm gear 13 etc., electro-motor 5 is installed on the motor installation portion 17 of reducing gearbox 4 at last.

Then, electro-motor 5 is installed on the motor installation portion 17 of reducing gearbox 4, is made splicing ear 5c and 5d and control unit installation portion 20 opposed, and output shaft 5a is connected on the worm screw 11.At this moment, owing to will combine with serration spline (serration) between the output shaft 5a of electro-motor 5 and the worm screw 11 or spline (spline) combines, therefore, mounting flange 5b is installed on the motor installation portion 17 as follows: Yi Bian electro-motor 5 is along the circumferential direction rotated, connect output shaft 5a and worm screw 11 on one side, in the moment that both connections are finished, splicing ear 5c and 5d, be installed in control unit installation portion 20 on control unit 19 in, the terminal base 24c face of synthetic resin system framework 24 contacts.

Like this, because when being installed in electro-motor 5 on the reducing gearbox 4, while along the circumferential direction being rotated, installs by electro-motor 5, therefore, by making splicing ear 5c and 5d along outstanding with the direction of axial quadrature, with regard to not damaging terminal base 24c or its periphery of control unit 19, can easily carry out the installation of electro-motor 5 on reducing gearbox 4 because of this splicing ear 5c and 5d.

By the way, under the situation that splicing ear 5c and 5d prolong along the outer peripheral face of electro-motor 5, when being screwed into electro-motor 5, splicing ear 5c and 5d may contact and damage terminal base 24c or its periphery of control unit 19, must carry out the assembling of electro-motor 5 extremely carefully, there is this pretty troublesome problem of erecting work, but in above-mentioned the 1st embodiment, when being screwed into electro-motor 5, splicing ear 5c and 5d can not produce interference with terminal base 24c or its periphery of control unit 19, can easily carry out erecting work.

Under this state, terminal base 24c on the synthetic resin system of the being formed on framework 24, is that face contacts with the splicing ear 5c of electro-motor 5 with 5d, as shown in figure 11, by from splicing ear 5c and 5d side, fixedly Screw 5o passes slotted hole 5e and screws on the terminal base 24c, can splicing ear 5c and 5d be fixedly mounted on the terminal base 24c with shortest distance.

Like this, can on the terminal base 24c of control unit 19, directly not be electrically connected the splicing ear 5c and the 5d of electro-motor 5 contiguously, and can directly the external connection terminals 15c～15f of torque sensor 15 be electrically connected with the through hole 25a～25d of control basal plate 25 via signal cable ground via feed cable ground.Therefore, can make to be electrically connected length for minimum between control unit 19 and electro-motor 5 and the torque sensor 15, reduce wiring resistance, can suppress electrical loss, and can reduce sneaking into of electrical noise.

In addition, owing to there is no need to be provided with the motor wire harness between electro-motor and control unit, therefore, the noise that radiates from the motor wire harness will reduce, and can alleviate the influence to radio noise.

And, on the synthetic resin system framework 24 in being formed at control unit 19, and the splicing ear 5c of electro- motor 5 and 5d bonded assembly terminal base 24c near, be formed with board 24b is installed, because this installation board 24b is fixed on the framework attachment face 20c, this framework attachment face 20c is formed on the motor installation portion 17 of reducing gearbox 4, therefore, can suppress terminal base 24c and on terminal base 24c, produce stress concentration, can make the rigidity raising of terminal base 24c because of Vehicular vibration produces the vibration different with reducing gearbox 4.

In addition, constitute the heat-producing power substrate 23 that is accompanied by of control unit 19, pass through thermal grease, smooth attachment face 20a on the control unit installation portion 20 of direct contact reducing gearbox 4, and reducing gearbox 4 is formed by in aluminium, aluminum alloy, magnesium and the magnesium alloy any, therefore, and can be with the heating of power substrate 23, be diffused on the big reducing gearbox 4 that becomes caloic (heat mass) of heat absorption capacity, can prevent reliably that power substrate 23 from becoming super heat.

And, by at the top of the torque sensor incorporating section 16 of reducing gearbox 4 configuration control unit 19, can shorten reducing gearbox 4 single-piece axial lengths, can realize miniaturization.

Under this state, after being installed to upper mounting bracket 6 and bottom installation bracket 7 on the body-side member, from vehicle body right flank side, with respectively with the continue adaptor union that continues of networks such as adaptor union and CAN of battery and earth point bonded assembly outside, be installed on the power connector 24d and signal connector 24e of control unit 19, thus, finish the assembling of electric power-assisted steering apparatus 1.Like this, owing to can the outside adaptor union that continues be connected to power connector 24d and signal connector 24e, therefore, can easily carry out both connections from vehicle body right flank side.At this moment, on upper mounting bracket 6, as shown in Figure 1,, be fixed with slip board 6f by the 6e of resin injection portion constituting on the chuck 6d that board 6a is installed.

When finishing the assembling of this electric power-assisted steering apparatus 1, rotate by the tilting bar 6g that makes upper mounting bracket 6, remove the tilt-lock state, under this state, making Steering gear 3 is that rotate at the center with the pivot 7c of bottom installation bracket 7, thus, can adjust obliquity.

And, when the not shown ignition lock that makes vehicle be in on-state, from battery during to power substrate 23 and control basal plate 25 supply capabilities, turn to aux. controls to handle by micro-control unit (MCU) execution, detected value according to torque sensor 15 and not shown car speed sensor calculates and turns to the auxiliary current command value.Turn to the auxiliary current command value and, carry out the current feedback processing according to this, calculate voltage instruction value by the detected motor current of motor current test section.This voltage instruction value is offered the gate driver circuit of power substrate 23, control H bridge circuit, thus motor drive current flows to electro-motor 5, drives electro-motor 5, to produce the required power steering of forward or reverse direction.

Therefore, produce the cooresponding power steering of steering torque with steering handwheel by electro-motor 5, this power steering passes to the output of steering shaft via worm screw 11 and worm gear 13, can steering handwheel be turned to thus.

Under this state, if chaufeur contacts with not shown steering handwheel when crumple takes place, the impulsive force that effect is forwards slided Steering gear 3, then as Figure 12～shown in Figure 14, the 6e of resin injection portion between the chuck 6d of upper mounting bracket 6 and the slip board 6f is sheared, thereby, in the mounting flange 3c of Steering gear 3 side, outer tube 3b is when absorbing impulsive force, slide with respect to interior pipe 3a, with head butt, thus as the bolt 18a that shrinks the stopper section, guaranteed necessary crumple stroke, Steering gear 3 shrinks.

When Steering gear 3 shrinks like this, being installed in its peripheral parts can be near control unit 19, yet, because this control unit 19 is disposed under the state of having guaranteed predetermined crumple stroke not the position that can interfere with moving-member, therefore can guarantee necessary crumple stroke, can not take place to interfere and the situation of obstruction crumple with moving-member.

By the way, crumple stroke during in order to ensure the generation crumple, considered to make the also situation of crumple of control unit 19, but as mentioned above, be difficult to control the crumple of the synthetic resin system framework 24 of this control unit 19, the problem of fluctuation appears in the amount of energy when having crumple, and in above-mentioned the 1st embodiment, in the guaranteeing of crumple stroke, do not consider the crumple of control unit 19, so can when crumple, guarantee stable amount of energy according to setting value.

And, in above-mentioned the 1st embodiment, the situation that the splicing ear 5c and the 5d of electro-motor 5 prolonged point-blank is illustrated, but be not limited thereto, shown in Figure 15 (a), also can be with splicing ear 5c and 5d once after the axial bending of electro-motor 5, make it extend to foreign side again along direction with axial quadrature, in the case, owing to can guarantee elasticity by the kink of splicing ear 5c and 5d, therefore, the unrelieved stress that produces in the time of can relaxing terminal and be connected with terminal base can prolong service life of splicing ear 5c and 5d.Similarly, shown in Figure 15 (b), it is given prominence to along the axial of electro-motor 5, then, make it extend to foreign side along direction with axial quadrature.

In addition, in above-mentioned the 1st embodiment, to being illustrated in the situation that splicing ear 5c and 5d is set on the electro-motor 5, terminal base 24c is set on control unit 19, but be not limited thereto, also can on electro-motor 5, terminal base be set, on control unit 19, splicing ear be set, and, also can be as shown in figure 16, both make splicing ear 31m and 31u with the cell side connecting portion of the motor-side connecting portion of electro-motor 5 and control unit 19.In the case, make under two splicing ear 31m and the 31u face state of contact, for example bolt 32 is run through and be inserted into the bolt-through that forms at splicing ear 31m and 31u and insert in the hole from splicing ear 31m side, the screwing nut 33 from the outstanding end of splicing ear 31u and it is tightened of this bolt 32, both can be combined as a whole thus.At this, bolt 32 and nut 33 constitute fastener, but be not limited to bolt 32 and nut 33 as fastener, also can on the either party of splicing ear 31m and 31u, form negative thread, from the opposing party's side bolt 32 is screwed this negative thread, also can use the fastener of other thread forms, or the fastener etc. of riveted joint form fastener arbitrarily.

In addition; be not limited to carry out the situation of splicing ear 31m and 31u with fastener; also can be as shown in figure 17; form weld part 34 by welding means such as fusion, spot welding, TIG (inert-gas tungsten-arc welding-tungsten electrode atmosphere gas arc welding) welding, make splicing ear 31m and 31u integrated.

And, also can be as shown in figure 18, for example the motor-side splicing ear is made the gynetype terminal 35m of the both ends open of circumferencial direction, the cell side connecting portion is made the male type terminal 35u that on the terminal base 24c of control unit 19, forms highlightedly, gynetype terminal 35m and male type terminal 35u are relatively rotated in a circumferential direction, both can freely be combined, in the case with installing and removing, also the motor-side splicing ear can be made male type terminal 35u, the cell side connecting portion is made gynetype terminal 35m.In addition, also can moving axially along electro-motor 5 by control unit 19 is constituted, come after electro-motor 5 is assembled to the motor installation portion 17 of reducing gearbox 4, make control unit 19 along the moving axially of electro-motor 5, so that male type terminal 35u combines with gynetype terminal 35m.

And, in above-mentioned the 1st embodiment, by Figure 11 especially as can be known, following situation is illustrated: the contact surface of splicing ear 5c and 5d, compare with the contact surface of the 5b of mounting flange portion of the motor installation portion 17 that contacts reducing gearbox 4 in the electro-motor 5 and to be positioned at the inboard, be formed on position away from motor installation portion 17.But be not limited to this, preferably as shown in figure 19, the contact surface that is configured to splicing ear 5c and 5d are contacted with terminal base 24c is consistent with the plane of the contact surface P1 that contacts with motor installation portion 17 that comprises the 5b of mounting flange portion.In the case, as mentioned above, when being assembled to electro-motor 5 on the reducing gearbox 4, owing to use serration spline or spline that the output shaft 5a of electro-motor 5 is combined with the worm screw 11 that is configured in the reducing gearbox 4, therefore, must connect while electro-motor 5 is along the circumferential direction rotated, when the slewing area of this circumferencial direction is narrow, can not go wrong, but under the situation that has enlarged slewing area, the 5b of mounting flange portion of the terminal base 24c of control unit 19 and electro-motor 5 interferes, may damage terminal base 24c, but by setting the contact surface that splicing ear 5c and 5d are contacted with terminal base 24c for, be in the plane of the contact surface that contacts with motor installation portion 17 that comprises the 5b of mounting flange portion, when assembling electro-motor 5, even under the situation of along the circumferential direction rotating significantly, also can prevent the interference of the terminal base 24c of 5b of mounting flange portion and control unit 19 reliably, can under the situation of defective component not, carry out the erecting work of electro-motor 5 swimmingly.In the case, the shape of splicing ear 5c and 5d also can have any shape, and key is, as long as make the contact surface of splicing ear 5c and 5d and cell side connecting portion, is formed in the plane of the attachment face that comprises electro-motor 5 and gets final product.

In addition, in above-mentioned the 1st embodiment, the situation that the present invention is applied to the right jiggering is illustrated, but be not limited thereto, under the situation that is applied to the LHS car, about reducing gearbox 4, electro-motor 5, and the configuration of control unit 19, clip vertical surface by the center shaft of Steering gear 3, face is symmetrically promptly at the right side of control unit 19 configuration electro-motor 5, the power connector 24d of control unit 19 and signal connector 24e are configured in the left side to get final product, and electro-motor 5 can be configured in vehicle outside, power connector 24d and signal connector 24e are configured in vehicle interior side.At this moment, shown in Figure 20 (a) and Figure 20 (b), splicing ear 5c is configured to the 5b of mounting flange portion with 5d: make the line L1 that is connected a pair of mounting flange 5b of portion, extending direction form right angle with the L2 of Central Line of splicing ear 5c and 5d, thus, general-duty electro-motor 5 can be applied in shown in the right jiggering shown in Figure 20 (a) and Figure 20 (b) in the LHS car.In addition, also can be as Figure 21 (a) with (b), carry out such setting: splicing ear 5c and 5d with electro-motor 5 are benchmark, make the mounting hole that the mounting flange 5b of portion is installed on the LHS car shown in the right jiggering shown in Figure 21 (a) and Figure 21 (b), be positioned at identical position, in the case, can the angle θ that extending direction constituted of the L2 of Central Line of the line L1 that connect a pair of mounting flange 5b of portion and splicing ear 5c and 5d at random be set.

Below, the 2nd embodiment of the present invention is described according to Figure 22 and Figure 23.

In the 2nd embodiment, the contact surface that replaces making motor-side connecting portion and cell side connecting portion for the situation of the axial rectangular direction of electro-motor, be direction with the axially parallel of electro-motor.

Promptly, in the 2nd embodiment, as shown in figure 22, set for: the electrical connection section 40 between the cell side connecting portion of the motor-side connecting portion of electro-motor 5 and control unit 19, to the height and position of the 2a of steering-wheel placing portion side, control unit 19 below the height and position of the 2a of steering-wheel placing portion side, that is, can be not outstanding from the end face of the 2a of the steering-wheel placing portion side of control unit 19.

For this reason, splicing ear 5c and 5d as the motor-side connecting portion of electro-motor 5, shown in Figure 23 (a)～(c), by constituting: radial direction board 41 as the lower part, its electro-motor 5 with the 5b of mounting flange portion circumferencial direction stagger 90 the degree positions, be in the roughly the same plane of the face of the control unit 19 side opposition sides of the 5b of mounting flange portion on, outstanding along radial direction; With axial board 42, it prolongs towards control unit 19 side direction the place aheads from the upper end of this radial direction board 41 and the axially parallel ground of electro-motor 5.At this, the front end of axial board 42, compared with the installation end face 43 that contacts with motor installation portion 17 reducing gearbox 4 electro-motor 5, forwards outstanding, and run through to be provided with at axial central portion and be used to run through the bigger patchhole 44 that runs through that inserts fix screw 46.

On the other hand, shown in Figure 23 (a)～(c), the terminal base 24c of control unit 19, from the chassis body 24a of control unit 19 with electro-motor central portion 5 opposed end faces, above-below direction, form to electro-motor 5 side-prominently, on terminal base 24c upper surface, be formed with the contact surface that sets coupling end daughter board 45 with the axially parallel ground of electro-motor 5.At this, on terminal base 24c, be formed with the negative thread 47 that screws fix screw 46, on coupling end daughter board 45, with negative thread 47 opposed positions, be formed be used to run through insert fix screw 46 run through patchhole 48.

And, on the output shaft 5a of electro-motor 5, coupler 52 being installed, coupler 52 for example carries out serration spline with the worm shaft 51 of the installation worm screw 11 of reducing gearbox 4 and combines.

And, the outstanding length adjustment of the splicing ear 5c of above-mentioned electro-motor 5 and the axial board 42 of 5d becomes: when being installed to electro-motor 5 on the reducing gearbox 4, with after the worm shaft 51 beginning serration splines of reducing gearbox 4 combine, its front end contacts with the coupling end daughter board 45 of the terminal base 24c of control unit 19 at the coupler 52 of electro-motor.

In addition; under the state on the terminal base 24c that electro-motor 5 is installed on the reducing gearbox 4 and splicing ear 5c and 5d are connected electrically in control unit 19; terminal base 24c and splicing ear 5c and 5d, as the diagram that the single-point of Figure 23 (a) is rule, protected cover 53 covers.At this, the height and position to the 2a of steering-wheel placing portion side of protective case 53 is configured to equate with the height and position to the 2a of steering-wheel placing portion side of control unit 19 or is lower.

And, on the motor installation portion 17 of reducing gearbox 4, be formed with tongue and groove (seal ?) auxiliary section 17a, on the installation end face 43 of electro-motor 5, be formed with the 5k of tongue and groove portion that cooperates with tongue and groove auxiliary section 17a.

According to the 2nd embodiment, shown in Figure 23 (b), under the worm screw incorporating section 12 of reducing gearbox 4 and electro-motor 5 and state that control unit 19 separates, installation and control unit 19 on the control unit installation portion 20 on the worm screw incorporating section 12 is installed to electro-motor 5 on the electro-motor installation portion 17 then.

At this moment, with the coupler 52 that is installed on the output shaft 5a of electro-motor 5, run through and be inserted in the worm screw incorporating section 12, begin to coupler 52 front ends with worm shaft 51 carry out serration spline till combining during, the front end of the axial board 42 on the splicing ear 5c of electro-motor 5 and the 5d can not contact with the terminal base 24c of control unit 19, both can not interfere mutually, therefore, can when self along the circumferential direction being rotated, electro-motor 5 easily carry out the serration spline combination of coupler 52 and worm shaft 51.

Then, coupler 52 combines beginning with the serration spline of worm shaft 51 after, under the coupling end daughter board 45 opposed states of the axial board 42 of splicing ear 5c that makes electro- motor 5 and 5d and the terminal base 24c of control unit 19, electro-motor 5 is pressed into motor installation portion 17 sides to reducing gearbox 4, the 5k of tongue and groove portion cooperates with tongue and groove auxiliary section 17a, electro-motor 5 is installed on the motor installation portion 17, and, the axial board 42 of splicing ear 5c and 5d contacts with 45 of the coupling end daughter boards of the terminal base 24c of control unit 19, and the patchhole 44 that runs through that is formed on the axial board 42 is aimed at the negative thread 47 of terminal base 24c and the patchhole 48 that runs through of coupling end daughter board 45.Under this state, fix screw 46 is screwed in negative thread 47 via running through patchhole 44,48, splicing ear 5c and the 5d with electro-motor 5 is electrically connected with the coupling end daughter board 45 of the terminal base 24c of control unit 19 thus.

Then, protective case 53 is installed, is made the terminal base 24c of its coverage control unit 19 and the splicing ear 5c and the 5d of electro-motor 5.

Like this; according to above-mentioned the 2nd embodiment; the splicing ear 5c of electro-motor 5 and 5d form the word of falling L shape by radial direction board 41 and axial board 42; and; because the contact surface that the terminal base 24c of control unit 19 contacts with axial board 42 at the midway location of the above-below direction of chassis body 24a; be formed on the direction with the axially parallel of electro-motor 5; therefore; height and position behind the protective case 53 that closes of the 2a of steering-wheel placing portion side is equated or lower than it with the height and position of control unit 19; from the 2a of steering-wheel placing portion side input impact load; outer tube 3b and upper mounting bracket 6 are received impact load at gear case 4 side draughts, can prevent from reliably simultaneously to bring baneful influence to carrying out the impact absorption function that stroke moves.In addition, can prevent following situation reliably: the motor-side connecting portion of electro-motor 5 and the cell side connecting portion of control unit 19 are more side-prominent to the 2a of steering-wheel placing portion than control unit 19, with key lock on the outer peripheral face of the outer tube 3b that is installed in Steering gear shown in Figure 22 3 with flange 55 or be installed in this key lock with 56 interference or approaching of the key lock assembly on flange 55, thereby become the obstacle on the package assembly.

And, the splicing ear 5c of electro-motor and 5d have so outstanding length: to the coupler 52 of electro-motor 5 be formed on reducing gearbox 4 on worm screw incorporating section 12 in worm shaft 51 begin to carry out serration spline till combining during in, the splicing ear 5c and the 5d of electro-motor keeps the state that separates in the axial direction with the terminal base 24c of control unit 19, therefore, when electro-motor 5 self along the circumferential direction being rotated, can prevent reliably that splicing ear 5c and 5d and terminal base 24c from interfering mutually for coupler 52 and worm shaft 51 usefulness serration splines are combined.

And, in above-mentioned the 2nd embodiment, to constituting the motor-side connecting portion by radial direction board 41 and axial board 42, the situation that is made of the cell side connecting portion terminal base 24c is illustrated, but be not limited thereto, also can constitute the cell side connecting portion, constitute the motor-side connecting portion by terminal base 24c by radial direction board 41 and axial board 42.

Below, the 3rd embodiment of the present invention is described with reference to Figure 24 and Figure 25.

The 3rd embodiment is to make splicing ear 5c and 5d in above-mentioned the 2nd embodiment have flexible and formation.

Promptly, in the 3rd embodiment, as Figure 24 and shown in Figure 25, the motor-side connecting portion of electro-motor 5 is by constituting as the lower part: the cable guide part 61 with insulativity, it has insulativity and the upper end is open, and having insulation gap wall 61a at the central portion of circumferencial direction, this cable guide part 61 is fixed near the installation end face 60 on the motor installation portion 17 that is installed on reducing gearbox 4 of electro-motor 5 the peripheral part; 2 radial direction board 61b are contained in them in 2 zones that the insulation gap wall 61a by this cable guide part 61 is divided into, and are connected with 5j with above-mentioned bus 5i; Flexible cable 62, its by joint piece 61c be bound up on these radial direction boards 61b from the outstanding protrusion of cable guide part 61, and extending to output shaft 5a side vertically, for example pipeline flexible joint cable that forms that they form L word shape by bending upward at front end flexible peripheral part is equipped with netted electric conductor constitutes; And terminal board 63, it is installed in the front end of this flexible cable 62.And, on the sidewall at the place, two ends of the circumferencial direction of cable guide part 61, forming by fastening pawl 66, these fastening pawl 66 fastenings are formed on the fastening hole 65a on the protective case 65.

On the other hand, shown in Figure 25 (a)～(c), the terminal base 24c of control unit 19 in above-mentioned the 2nd embodiment 45 of coupling end daughter boards are formed with insulation gap wall 61a bonded assembly insulation gap wall 71 in the cable guide part 61 with electro-motor 5, have same structure with Figure 23 (a)～(c).

In the 3rd embodiment; the height and position of the end face of the 2a of the steering-wheel placing portion side of protective case 65; equate with the height and position of the end face of the 2a of the steering-wheel placing portion side of control unit 19 or lower, can prevent that protective case 65 is more side-prominent to the 2a of steering-wheel placing portion than the end face of the 2a of the steering-wheel placing portion side of control unit 19 than it.

According to the 3rd embodiment, similarly installing under the state of control unit 19 with the above-mentioned the 1st and the 2nd embodiment on the reducing gearbox 4, when being assembled to electro-motor 5 on the reducing gearbox 4, shown in Figure 24 (b) and 25 (a), make the flexible cable 62 of electro-motor 5 become the state that is bent into L word shape, so that terminal board 63 prolongs along radial direction.Like this, by flexible cable 62 being become be bent into the state of L word shape, the terminal base 24c of flexible cable 62 and terminal board 63 and control unit 19 just can not interfere in a circumferential direction, and the coupler 52 that can easily be installed on the output shaft 5a of electro-motor 5 combines with the serration spline of the worm shaft 51 of the worm screw incorporating section 12 of reducing gearbox 4.

And, begun under the state of serration spline combination at coupler 52 and worm shaft 51, cable guide part 61 and terminal base 24c are installed to electro-motor 5 on the motor installation portion 17 of reducing gearbox 4 opposed to each other.Under this state, shown in Figure 25 (b), by stretching the kink of flexible cable 62, terminal board 63 is contacted with 45 of the coupling end daughter boards of the terminal base 24c of control unit 19, the patchhole 64 that runs through that is formed at terminal board 63 is aimed at the negative thread 47 of terminal base 24c and the patchhole 48 that runs through of terminal clamp 45.Under this state, as Figure 25

(b) and (c), fix screw 46 is screwed on negative thread 47 via running through patchhole 64,48, thus, the terminal board 63 of electro-motor 5 is electrically connected with the coupling end daughter board 45 of the terminal base 24c of control unit 19.At this moment,, on the terminal base 24c of control unit 19, also be formed with insulation gap wall 71, therefore, can prevent reliably that flexible cable 62 is in contact with one another and short circuit owing on the cable guide part 61 of electro-motor 5, be formed with insulation gap wall 61a.

Then; shown in Figure 25 (d); make the fastening hole 65a fastening that is formed at protective case 65 medial surfaces on the fastening pawl 66 that is formed on cable guide part 61 sides, protective case 65 is installed in the mode of the cable guide part 61 of the terminal base 24c of coverage control unit 19 and electro-motor 5.

Like this; in the 3rd embodiment; because with the motor-side connecting portion that is electrically connected between electro-motor 5 and the control unit 19 and cell side connecting portion; projecting height to the 2a of steering-wheel placing portion side; be set at control unit 19 below the projecting height of the 2a of steering-wheel placing portion side; therefore; make outer tube 3b and upper mounting bracket 6 carry out stroke when moving to reducing gearbox 4 sides owing to impact load from the 2a of steering-wheel placing portion side; be installed in key lock on the outer tube 3b of Steering gear 3 with installing components such as flange 55 or key lock assemblies 56; can not produce and interfere, can bring into play the impact absorption function fully with protective case 65.In addition, when the assembling electric power-assisted steering apparatus, sufficient working space can be guaranteed, erecting work can be easily carried out.

And, because the motor-side connecting portion of electro-motor 5 has flexible cable 62, therefore,, also can utilize flexible this manufacturing errors that absorbs of flexible cable 62 even electro-motor 5 and reducing gearbox 4 produce manufacturing errors.

And, in above-mentioned the 3rd embodiment, constitute the motor-side connecting portion by interior cable guide part 61, joint piece 61c, flexible cable 62 and the terminal board 63 that radial direction board 61b is housed, constitute the cell side connecting portion by terminal base 24c, and the situation of such formation is illustrated, but be not limited thereto, also can constitute the cell side connecting portion, constitute the motor-side connecting portion by terminal base 24c by cable guide part 61, joint piece 61c, flexible cable 62 and terminal board 63.

In addition, in above-mentioned the 3rd embodiment, the situation of flexible cable 62 is illustrated to tightening fixedly on the radial direction board 61b of the interior cable guide part 61 that is loaded on insulativity, but be not limited thereto, also can imbed insulativity cable guide part, directly derive flexible cable 62 from the peripheral part of electro-motor 5 at the peripheral part of electro-motor 5.In addition, flexible cable with using insulation the flexible cable of the electric conductor of the central part that has been covered replace having on the outer peripheral face under the situation of pipeline flexible joint cable of netted electric conductor, just there is no need to make the cable guide part to have insulativity, and also can omit cable guide part self.

And, in the above-mentioned the 2nd and the 3rd embodiment, to with fix screw 46 fixedly the situation of splicing ear 5c, the 5d of electro-motor 5 and terminal board 63 and the terminal base 24c of control unit 19 be illustrated, but be not limited thereto, also can be with the above-mentioned the 1st to execute mode the same, with fastener fixing motor side connecting portion and cell side connecting portions such as bolt or rivets, perhaps fix by welding means such as fusion, spot welding and TIG welding.

In addition, in the above-mentioned the 2nd and the 3rd embodiment, to the coupler 52 of electro-motor 5 worm shaft 51 with reducing gearbox 4 is illustrated by the situation that serration spline combines, but be not limited thereto, also the spline combination can be carried out, associated methods arbitrarily can be used.

And, in above-mentioned the 1st～the 3rd embodiment, external connection terminals 15c～15f bending with torque sensor 15 is L word shape, and situation about running through among the through hole 25a～25d that is inserted into control basal plate 25 is illustrated, but be not limited thereto, for easily being run through, external connection terminals 15c～15f is inserted among through hole 25a～25d, and also can be at the guiding parts that a side setting of inserting external connection terminals 15c～15f has funnelform spigot surface that runs through of through hole 25a～25d.

In addition, in above-mentioned the 1st～the 3rd embodiment, the situation that external connection terminals 15c～15f with torque sensor 15 is formed L word shape is illustrated, but be not limited thereto, also can make external connection terminals 15c～15f is linearity, connection bonding land along being formed on the control basal plate 25 is electrically connected by soldering or fusion etc., perhaps external connection terminals is made the clamping terminal and is clamped on the control basal plate 25.

And, in above-mentioned the 1st～the 3rd embodiment, to the smooth attachment face 20a of the control unit installation portion 20 of reducing gearbox 4 is that situation with the plane of the orthogonality of center shaft of Steering gear 3 is illustrated, but be not limited thereto, also can make smooth attachment face 20a for respect to the face of the face tilt of the orthogonality of center shaft of Steering gear 3.

In addition, in above-mentioned the 1st～the 3rd embodiment, electro-motor 5, control unit 19 and adaptor union 24d, 24e, along with the line configuration in-line of the orthogonality of center shaft of Steering gear 3, and this situation is illustrated, but be not limited thereto, also the line configuration in-line that can intersect along center shaft with Steering gear 3.

And, in above-mentioned the 1st～the 3rd embodiment, the power connector 24d of control unit 19 and signal connector 24e, their connection is positioned at the right-hand member side with opening, and this situation is illustrated, but be not limited thereto, also can make to connect to be axial direction, aerial lug axially is installed from Steering gear 3 along Steering gear 3 with opening.

In addition, in above-mentioned the 1st～the 3rd embodiment, under the situation that constitutes control unit 19, at first, with Screw power substrate 23 is fixed on the smooth attachment face 20a, fixing synthetic resin system framework 24 then, with Screw control basal plate 25 is fixed on this synthetic resin system framework 24, and this situation is illustrated, but be not limited thereto, also power substrate 23 and control basal plate 25 can be installed on the synthetic resin system framework 24, and then synthetic resin system framework 24 is fixed on the smooth attachment face 20a, and, also a part and the power substrate 23 of synthetic resin system framework 24 can be tightened together.

And, in above-mentioned the 1st～the 3rd embodiment, power substrate 23 is made of the metal substrate with high thermoconductivity, and this situation is illustrated, but also can make metal substrate separately, power substrate 23 is installed on the smooth attachment face 20a of control unit installation portion 20 across metal substrate and thermal grease, and, also the power module substrate 23 that is made of metal substrate can be installed on the smooth attachment face 20a across additional metals substrate and thermal grease again.

In addition, in above-mentioned the 1st～the 3rd embodiment, the situation of having used the electric brush type motor as electro-motor 5 is illustrated, but be not limited thereto, also can use brushless motor, in the case, as long as splicing ear 5c and 5d are connected to the supply side of each excitation coil mutually, and the gate driver circuit of grid of the inverter circuit that for example has field effect transister (FET) that drives brushless motor being installed on power substrate 23 and being utilized pulse width modulating signal to drive the field effect transister of inverter circuit gets final product.

Below, the 4th embodiment of the present invention is described with reference to Figure 26～Figure 29.

About the 4th embodiment, be in above-mentioned the 2nd embodiment, when being installed to electro-motor 5 on the reducing gearbox 4, the terminal base 24c of motor- side splicing ear 5c and 5d and control unit 19 sides can not interfered.

That is, in the 4th embodiment,, on the front end face of the output shaft 5a of electro-motor 5, be formed with splined hole 81 (with reference to Figure 27) as Figure 26 and shown in Figure 27.In addition, electro-motor 5 as on the gear hub 4 of reducing gearbox as the motor mounting flange 17 of motor installation portion near, have 2 splicing ear 5c and 5d (with reference to Fig. 5).These motor- side splicing ear 5c and 5d are made of metal sheets such as copper coins, are that the leading section bending is to the L of gear shell-side word shape.

Be built in Worm gear mechanism 50 in the gear hub 4 by constituting as the lower part: worm shaft 51, it forms worm screw 11; Worm gear (not shown), itself and worm screw 11 mesh, and on the motor-side end of worm shaft 51, form the castellated shaft 82 that cooperates with above-mentioned splined hole 81 with worm shaft 51.

As shown in figure 26, control unit 19 has and forms flat 2 splicing ear 83a and 83b near the motor mounting flange 17 of gear hub 4.These control unit sides splicing ear 83a and 83b are side-prominent to electro-motor, and as shown in figure 27, on the plane parallel with the output shaft 5a of electro-motor 5, coincidence contacts with face with 5d with motor-side splicing ear 5c.

At this, as shown in figure 27, if with the length of motor- side splicing ear 5c and 5d and control unit side splicing ear 83a and 83b superposed part (below, be called " overlap length "), be made as L1, the spline fitted length of the worm shaft 51 of the output shaft 5a of electro-motor 5 and Worm gear mechanism 50 is made as L2, the tongue and groove length of fit of the tongue and groove auxiliary section 17a of the 5k of tongue and groove portion of electro-motor 5 and gear hub 4 is made as L3, then in the present embodiment, L2＞L3＞L1 is just arranged.

In addition, as shown in figure 28, if will from be formed on the electro-motor 5 as the shell-side end face 43 of the attachment face of mounting flange 5b distance to the front end of motor- side splicing ear 5c and 5d, be made as L4; Distance from the motor-side end face 17b of the mounting flange 17 that is formed at gear hub 4 to the motor-side end face of worm shaft 51 is made as L5; Will be from the motor-side end face of motor mounting flange 17, be made as L6 to the distance of the front end of control unit side splicing ear 83a and 83b; Distance that will be from the shell-side end face 43 of motor flange 5b to the front end of motor output shaft 5a is made as L7; The output shaft 5a of electro-motor 5 will soon be cooperated motor- side splicing ear 5c and 5d before with worm shaft 51, and the gap value between control unit side splicing ear 83a and the 83b, be made as L8 (with reference to Figure 29), then in the present embodiment, (L4+L5+L6)＜L7 is just arranged, and (L4+L5+L6+L8)=L7.

And, at the front end of control unit side splicing ear 83a and 83b not from the motor mounting flange 17 of gear hub 4 under the side-prominent situation of electro-motor, distance L 6 is a negative value.In addition, at the front end of motor- side splicing ear 5c and 5d not from the motor flange 5b of electro-motor 5 under the side-prominent situation of gear hub, distance L 4 is a negative value.

In such structure, Figure 29 represents that the motor output shaft 5a of electro-motor 5 is about to and worm shaft 51 spline fitted state before.As shown in the drawing, as can be known, the motor output shaft 5a of electro-motor 5 be about to worm shaft 51 spline fitted before, still underlapped between motor- side splicing ear 5c and 5d and control unit side splicing ear 83a and the 83b.Its reason is, distance L 4, distance L 5 and distance L 6 and (L4+L5+L6), less than distance L 7 from the shell-side end face 43 of the 5b of mounting flange portion to the front end face of motor output shaft 5a, described distance L 4 is the distances from the shell-side end face 43 of the 5b of mounting flange portion to the front end of motor- side splicing ear 5c and 5d, described distance L 5 is the distances from the motor-side end face of motor mounting flange 17 to the motor-side end face of worm shaft 51, and described distance L 6 is the distances from the motor-side end face 17b of motor mounting flange 17 to the front end of control unit side splicing ear 83a and 83b.

Thereby, in above-mentioned the 4th embodiment, make distance L 4, distance L 5 and distance L 6 and (L4+L5+L6), less than distance L 7 from the shell-side end face 43 of motor flange 5b to the front end face of motor output shaft 5a, described distance L 4 is the distances from the shell-side end face 43 of motor flange 5b to the front end of motor- side splicing ear 5c and 5d, described distance L 5 is the distances from the motor-side end face of motor mounting flange 17 to the motor-side end face of worm shaft 51, described distance L 6 is the distances from the motor-side end face of motor mounting flange 17 to the front end of control unit side splicing ear 83a and 83b, thus, when being installed to electro-motor 5 on the gear hub 4, before the motor output shaft 5a and worm shaft 51 spline fitted of electro-motor 5, motor-side splicing ear 5c can not overlap with 83b with control unit side splicing ear 83a with 5d and contact with face, therefore, can easily carry out the motor output shaft 5a of electro-motor 5 and the phase place of worm shaft 51 aligns.

In addition, before the splicing ear 83a of the splicing ear 5c of electro- motor 5 and 5d and control unit 19 and 83b are overlapping, the motor output shaft 5a of electro-motor 5 and worm shaft 51 carry out spline fitted, thus, electro-motor 5 can not move along the direction except axial and circumferential, therefore, the electrical connection section that can prevent to make electro-motor 5 and control unit 19 contacts with unnecessary part and causes electrical connection section to produce damaged and distortion.

In above-mentioned the 4th embodiment, illustration the motor output shaft 5a of electro-motor 5 and the situation of worm shaft 51 spline fitted, but be not limited thereto, for example, even the motor output shaft 5a of electro-motor 5 and worm shaft 51 cooperate by coupler etc., also can use the present invention, in addition, also can replace the situation of output shaft 5a and worm shaft 51 spline fitted, and it carries out the serration spline cooperation.

In addition, in above-mentioned the 4th embodiment, illustration such situation: the motor output shaft 5a of electro-motor 5 and the spline fitted length L 2 of worm shaft 51, tongue and groove length of fit L3 greater than the tongue and groove auxiliary section 17a of the 5k of tongue and groove portion of electro-motor 5 and gear hub 4, but also can make the spline fitted length L 2 of the motor output shaft 5a and the worm shaft 51 of electro-motor 5, tongue and groove length of fit L3 less than the tongue and groove auxiliary section 17a of the 5k of tongue and groove portion of electro-motor 5 and gear hub 4, by making L3＞L2＞L1, even under the very big situation of the quality of electro-motor 5 (situation that the axial length of motor body is very long), owing to can't correspondingly become big from the installation length of the outstanding electro-motor 5 of gear hub 4, therefore, can be installed on the gear hub 4 by the electro-motor that quality is big.

Below, the 5th embodiment of the present invention is described with reference to Figure 30.

In the 5th embodiment, identical with above-mentioned the 3rd embodiment, making the motor-side splicing ear is flexible structure, and making control unit side splicing ear is rigid construction.

In the 5th embodiment, Figure 30 represents the inner structure of the electro-motor 5 identical with Fig. 8 in above-mentioned the 1st embodiment; Figure 31 (a) expression assembles the shape of splicing ear 5c, 5d before and the position of terminal base 24c with the mounting flange 5b of electro-motor 5 and the motor installation portion 17 of reducing gearbox 4; Figure 31 (b) expression assembles terminal base 24c afterwards and the coupled condition of splicing ear 5c, 5d with mounting flange 5b and motor installation portion 17.

Shown in Figure 31 (a), each splicing ear 5c, 5d are the tabular metal partss that is bent into L word shape, and they are by constituting as the lower part: the 1st elasticity board 5p, and its axis direction along electro-motor 5 extends; With the 2nd elasticity board 5r, along extending with the direction of the axle center quadrature of electro-motor 5, each splicing ear 5c, 5d are the flexible structure that elastic deformation can take place on the axis direction of electro-motor 5 from the front end of the 1st elasticity board 5p for it.In addition, be equipped with slotted hole 5e at the leading section of the 2nd elasticity board 5r, this slotted hole 5e is used to run through the insertion fix screw.This slotted hole 5e runs through setting with long axis direction along the mode that the length direction of the 2nd elasticity board 5r extends.And each splicing ear 5c, 5d form: the 2nd elasticity board 5r extends with the 1st tolerance δ 1 with respect to the flange surface 5b1 of mounting flange 5b.

In addition, the framework attachment face 20c of periphery (rear vehicle end face) setting of (assembling) portion 17 is installed at motor, by being installed, board 24b is fixed with terminal base 24c, this terminal base 24c also forms: terminal surface (with the opposed face of splicing ear 5c, 5d) is positioned at the position at a distance of the 2nd tolerance δ 2 with respect to the flange surface 17a of motor installation portion 17, for can not be to the rigid construction of splicing ear 5c, the distortion of 5d side.At this, on terminal surface, form tapped bore 24c1.

And, shown in Figure 31 (b), make each other flange surface 5b1,17a butt, assemble this mounting flange 5b and motor installation portion 17.At this moment, between splicing ear 5c, 5d and terminal base 24c, there is gap (with the 1st tolerance δ 1 and the 2nd tolerance δ 2 additions and distance), but the 2nd elasticity board 5r by making splicing ear 5c, 5d is to terminal base 24c side shifting, make the 1st elasticity board 5p and the 2nd elasticity board 5r that elastic deformation take place, come when absorbing above-mentioned gap, the front of the 2nd elasticity board 5r to be contacted with terminal base 24c face.Then, from splicing ear 5c, 5d side, fix screw 5o is passed among the tapped bore 24c1 that slotted hole 5e screws terminal base 24c, thereby splicing ear 5c, 5d and terminal base 24c are connected.

Next, the action to above-mentioned the 5th embodiment describes.

At first, in order to assemble electric power-assisted steering apparatus, the same with above-mentioned the 1st embodiment, in the torque sensor incorporating section 16 of reducing gearbox 4, fixed configurations torque sensor 15 makes the peripheral part of the front end edge Steering gear 3 of its external connection terminals 15c～15f prolong to rear view of vehicle.

Then, installation and control unit 19 on the control unit installation portion 20 of reducing gearbox 4, then, on reducing gearbox 4, install after steering shaft 2, Steering gear 3, worm screw 11 and the worm gear 13 etc., electro-motor 5 is installed on the motor installation portion 17 of reducing gearbox 4 at last.

Then, the flange surface 5b1 by making mounting flange 5b and the flange surface 17a of motor installation portion 17 connect butt, make the terminal base 24c of splicing ear 5c, the 5d of electro-motor 5 and control unit 19 opposed, and the output shaft 5a of electro-motor 5 is connected on the worm screw 11.

At this moment, the 2nd elasticity board 5r by making splicing ear 5c, 5d is to terminal base 24c side shifting, make the 1st elasticity board 5p and the 2nd elasticity board 5r that elastic deformation take place, be present in gap between splicing ear 5c, 5d and the terminal base 24c (with the 1st tolerance δ 1 and the 2nd tolerance δ 2 additions and distance) and be absorbed, the front of the 2nd elasticity board 5r is contacted with terminal base 24c face.Then, by fix screw 5o being passed slotted hole 5e screw the terminal base 24c, splicing ear 5c, 5d and terminal base 24c are coupled together from splicing ear 5c, 5d side.

Thereby, according to present embodiment, the splicing ear 5c of flexible structure, 5d forms: the 2nd elasticity board 5r extends with the 1st tolerance δ 1 with respect to the flange surface 5b1 of mounting flange 5b, the terminal base 24c of rigid construction also forms: terminal surface is (with splicing ear 5c, the opposed face of 5d) the flange surface 17a with respect to motor installation portion 17 is positioned at the position of the 2nd tolerance δ 2 apart, do not need splicing ear 5c, 5d and terminal base 24c are configured on the high-precision position, do not need to make splicing ear 5c yet, 5d and terminal base 24c are flexible structure, therefore, can realize the reduction of manufacturing cost.

In addition, when splicing ear 5c, 5d and terminal base 24c are electrically connected, making splicing ear 5c, 5d that elastic deformation take place with after terminal base 24c face contacts, by fix screw 5o being passed the slotted hole 5e that is formed on splicing ear 5c, the 5d screws on terminal base 24c from splicing ear 5c, 5d side, splicing ear 5c, 5d and terminal base 24c are connected, by on splicing ear 5c, 5d, forming slotted hole 5e, fluctuation in the time of can absorbing splicing ear 5c, 5d and terminal base 24c manufacturing, therefore, can further realize the reduction of manufacturing cost.

In addition, the splicing ear 5c of flexible structure, 5d is the structure of such L word shape: when making the 2nd elasticity board 5r to terminal base 24c side shifting, elastic deformation will take place in the 1st elasticity board 5p and the 2nd elasticity board 5r, even at splicing ear 5c, there is the gap between 5d and the terminal base 24c, because splicing ear 5c, 5d is to terminal base 24c side generation elastic deformation, the gap can be absorbed and face is electrically connected contiguously, therefore, can relax splicing ear 5c, unrelieved stress when 5d is connected with terminal base 24c can prolong splicing ear 5c, the service life of 5d and terminal base 24c.

In addition, when being installed to electro-motor 5 on the gear hub 4, while along the circumferential direction being rotated, installs by electro-motor 5, but because splicing ear 5c, the 5d of electro-motor 5 are forwards not outstanding from the flange surface 5b1 of mounting flange 5b, therefore, can not damage the terminal base 24c and the periphery thereof of control unit 19 because of this splicing ear 5c, 5d, can easily electro-motor 5 be assembled on the reducing gearbox 4.

And, because the terminal base 24c that on synthetic resin system framework 24, forms and splicing ear 5c, the 5d of electro-motor 5, by fix screw 5o, install securely with shortest distance, therefore, can make to be electrically connected length for the shortest between control unit 19 and the electro-motor 5, it is minimum can making wiring resistance, electrical loss can be suppressed, and sneaking into of electrical noise can be reduced.In addition, owing to need the motor wire harness be set at electro- motor 5 and 19 of control units, therefore, the noise that radiates from the motor wire harness will reduce, and the influence to radio noise is alleviated.

And, in above-mentioned the 5th embodiment, splicing ear 5c, 5d are set on electro-motor 5, terminal base 24c is set on control unit 19, and this situation is illustrated, but be not limited thereto, also can on electro-motor 5, terminal base be set, on control unit 19, splicing ear be set.

In addition, in above-mentioned the 5th embodiment, electro-motor 5, control unit 19 and power connector 24d and signal connector 24e, along with the line of the orthogonality of center shaft of Steering gear 3, the configuration in-line, and this situation is illustrated, but be not limited thereto the line configuration in-line that also can intersect along center shaft with Steering gear 3.

In addition, in above-mentioned the 5th embodiment, used the electric brush type motor, and this situation has been illustrated, but be not limited thereto, also can use brushless motor as electro-motor 5.

In addition, in Figure 30 and Figure 31 (a) of above-mentioned the 5th embodiment, on splicing ear 5c, the 5d of electro-motor 5, be formed with slotted hole 5e, this slotted hole 5e long axis direction extends along the length direction of the 2nd elasticity board 5r, and this situation is illustrated, but be not limited thereto, also can be shown in figure 32, on the 2nd elasticity board 5r of splicing ear 5c, 5d, form slotted hole 5e along the mode that the Width of the 2nd elasticity board 5r extends with long axis direction.

Below, the 6th embodiment of the present invention is described with reference to Figure 33～Figure 39.

Used brushless motor as electro-motor in the 6th embodiment.

That is, in the 6th embodiment, Figure 33 is the block diagram of an example that expression is applied in the situation of right jiggering; Figure 34 is the exploded perspective view of Figure 33; Figure 35 is the block diagram of pulling down the state behind the electro-motor of expression Figure 33; Figure 36 is the longitudinal section of reducing gearbox; Figure 37 is the block diagram of electro-motor; Figure 38 is the exploded perspective view of electro-motor; Figure 39 is the block diagram of control unit.

In Figure 33, the 1st, pillar is assisted electric power-assisted steering apparatus, on steering handwheel (not shown), be connected with steering shaft 2, steering shaft 2 can rotate freely and be loaded in the ground in the Steering gear 3, on Steering gear 3, be connected with reducing gearbox 4, on this reducing gearbox 4, be equipped with the electro-motor 5 that constitutes by brushless motor, electro-motor 5 axially along extending with the direction of the axial quadrature of Steering gear 3.

Here, Steering gear 3 is the double-sleeve structure of pipe 3a in adopting and outer tube 3b, and the impact energy when absorbing crumple at the connecting portion place with reducing gearbox 4 is guaranteed the crumple stroke of being scheduled to.In addition, the outer tube 3b of Steering gear 3 and reducing gearbox 4 are installed in body side by upper mounting bracket 6 and bottom installation bracket 7.

Bottom installation bracket 7 is by forming with lower member: board 7a is installed, and it is installed on the body-side member (not shown); With a pair of supporting board 7b, they extend in parallel in the predetermined compartment of terrain of lower surface maintenance of this installation board 7a.In addition, the front end of supporting board 7b by pivot 7c, is connected on the support 4b that is integrally formed at lid 4a free to rotately, this lid 4a be provided in reducing gearbox 4 lower end side, be the vehicle body front side.

In addition, upper mounting bracket 6 has: board 6a is installed, and it is installed on the body-side member (not shown); Square box shape support 6b, it is formed on this installation board 6a; And leaning device 6c, it supports the outer tube 3b that is formed on the Steering gear 3 on this square box shape support 6b.

In addition, leaning device 6c rotates by making tilting bar 6g, removes bearing state, can be the center with the pivot 7c of bottom installation bracket 7 thus, up and down Steering gear 3 is carried out the obliquity adjustment.

And as shown in figure 36, steering shaft 2 is by constituting as the lower part: input shaft 2b, and its upper end is connected on the steering handwheel (not shown); With output shaft 2d, it is connected with the lower end of this input shaft 2b by torsion bar 2c, and covers torsion bar 2c.

In addition, as Figure 34～shown in Figure 36, casting forming forms reducing gearbox 4 by for example carrying out in material, for example aluminium, aluminum alloy, magnesium and the magnesium alloy with high thermal conductivity any.This reducing gearbox 4 has: worm screw incorporating section 12, and it takes in the output shaft 5f bonded assembly worm screw 11 with electro-motor 5; Worm gear incorporating section 14, its downside in this worm screw incorporating section 12 have the center shaft with the orthogonality of center shaft of worm screw incorporating section 12, and take in and worm screw 11 ingear worm gears 13; Torque sensor incorporating section 16, its one and be connected the rear side of this worm gear incorporating section 14 coaxially is used to take in torque sensor 15; Motor installation portion 17, the open end face that it is formed at worm screw incorporating section 12 is used to install electro-motor 5; Post installation portion 18, the aft end face that it is formed at torque sensor incorporating section 16 is used to install the mounting flange 3c that is formed on these Steering gear 3 leading sections; And control unit installation portion 20, it is across the part of worm screw incorporating section 12 and worm gear incorporating section 14, is formed in the central axis plane orthogonal with worm gear incorporating section 14 and torque sensor incorporating section 16, is used for installation and control unit (ECU) 19.Here, in order to improve the adaptation of control unit installation portion 20 and control unit 19, control unit installation portion 20 be cut be processed into plane.

And reducing gearbox 4 is connected under the state of post installation portion 18 at the mounting flange 3c that makes Steering gear 3, is fixed on the Steering gear 3 by bolt 18a.

At this, as shown in figure 36, torque sensor 15 constitutes: by magnetic the input shaft 2b of steering shaft 2 and the twisting states between the output shaft 2d are detected, utilize a pair of magnetic test coil 15a and 15b as the moment of torsion detecting element to detect the steering torque that is delivered to steering shaft.

Spiral head and spiral tail at these a pair of magnetic test coil 15a and 15b are connected with external connection terminals 15c respectively, 15d and 15e, 15f, described external connection terminals 15c, 15d and 15e, 15f is along outstanding to the outside abreast with the direction of the orthogonality of center shaft of Steering gear 3, the protrusion of these external connection terminals 15c～15f forms L word shape in the ground bending of the central axes of central portion and Steering gear 3, as shown in figure 34, outstanding upward from opening 22, this opening 22 is formed on the spigot surface 21, this spigot surface 21 forms with control unit installation portion 20 with meeting at right angles, is used to guide the lower surface of control unit 19.

In addition, as Figure 37 and shown in Figure 38, electro-motor 5 is by constituting as the lower part: the framework 5a of round-ended cylinder shape is arranged, and its front end is open; Connecting portion 5b, it covers the front end of this framework 5a, and is installed on the reducing gearbox 4; Motor stator 5c, it is provided in the framework 5a; Output shaft 5f, it runs through and is inserted in this motor stator 5c, and can rotate freely by the back side bearing 5d that is fixed on framework 5a bottom and be fixed on front side bearing 5e supporting on the connecting portion 5b; Surface magnet-type motor rotor 5g, its be fixed on this output shaft 5f with the opposed position of motor stator 5c on, on the surface of motor rotor 5g, be formed with permanent magnet; And as the resolver 5h of rotor angle detector, its be provided in this motor rotor 5g with the opposed position of connecting portion 5b on, be used for the corner of detection rotor.

At this, as shown in figure 38, on framework 5a, on the positions of 180 degree apart of opening distolateral outer peripheral face, be formed with flange part 5i.

In addition, on connecting portion 5b, as shown in figure 38, with the opposed position of flange part 5i, be formed with flange installation portion 5j; And on the outer peripheral face of the midway location of flange installation portion 5j, be formed with opening 5k, this opening 5k makes electric contact described later be exposed to the outside, and on the framework 5a side end face of connecting portion 5b, be formed with the 5m of tongue and groove portion that combines with framework 5a tongue and groove, on the position of staggering in a circumferential direction with flange installation portion 5j of the opposition side of the 5m of this tongue and groove portion, be formed with mounting flange 5n, this mounting flange 5n is installed on the motor installation portion 17 of above-mentioned reducing gearbox 4, is formed with the 5o of tongue and groove portion that combines with motor installation portion 17 tongue and grooves in the inboard of this mounting flange 5n.

And, on motor stator 5c, in insulation shell 5p cylindraceous, be equipped with stator 5q, the bus (not shown) that the terminal bonded assembly of the three-phase coil on being wound on stator 5q is roughly circular is equipped with the outside motor terminal tm1～tm3 that connects with electric contact of the conduct that is shaped by the resin insert molding.

These motor terminal tm1～tm3 is by constituting as the lower part: protrusion 5r, its from the front end face of the insulation shell 5p of motor stator 5c to outstanding with the radial direction of the orthogonality of center shaft of electro-motor 5; Extension 5s, it is from the upper end of this protrusion 5r and the parallel extension forwards of center shaft of electro-motor 5; And portion of terminal 5t, its front end from this extension 5s extends to the direction identical with protrusion 5r.

And, back side bearing 5d and front side bearing 5e are made of deep groove ball bearing, the mounting ring of back side bearing 5d cooperates with inside diameter to the projection that is formed at framework 5a bottom, in the axial direction not shown safety washer is inserted between the end face of mounting ring of the bottom of projection and back side bearing 5d, to apply axial precompressed compression.On the other hand, the mounting ring of front side bearing 5e cooperates with connecting portion 5b, fixes by not shown stopper ring in the axial direction.

And resolver (resolver) 5h has: resolver stator 5v, and it is fixed on the inner peripheral surface of resolver housing 5u, and this resolver housing 5u is fixed in the connecting portion 5b; With resolver rotor 5w, it is fixed on the output shaft 5f, and this output shaft 5f runs through and is inserted in this resolver stator 5v.

When from excitation signal f (the t)=Asin (ω t) of exterior signal processing circuit input sine wave, resolver stator 5v output and the cooresponding sinusoidal waveform of rotational angle theta of rotor and the resolver signal Ys (=ksin (θ) f (t)) and the Yc (=kcos (θ) f (t)) of cosine wave.

Therefore, have these excitation signals of the input and output of being used for f (t) and resolver signal Ys, Yc's, the resolver terminal tr1 that constitutes by a pair of excitation signal input terminal and resolver signal output terminal respectively, tr2, and tr3, these resolver terminals tr1～tr3 is formed on the outer peripheral face of resolver housing 5u, prolong along radial direction, and concurrently from the center shaft of the output shaft 5f of protrusion 5x and electro-motor 5, promptly forwards outstanding along the direction vertical with the end face of connecting portion 5b, described protrusion 5x is outstanding to foreign side from the opening 5k that is formed at connecting portion 5b.

On the other hand, on protrusion 5x, be formed with engagement groove 5y at aft end face, this engagement groove 5y engages with the protrusion 5r of motor terminal tm1～tm3 of motor stator 5c, front end face at protrusion 5x is formed with engagement groove 5z, and engagement groove 5z engages with the extension 5s of motor terminal tm1～tm3.

And, in framework 5a and connecting portion 5b, installed under the state of motor stator 5c, back side bearing 5d, front side bearing 5e, output shaft 5f, motor rotor 5g and resolver 5h, be fixed on by flange part 5i screw thread on the flange installation portion 5j of connecting portion 5b framework 5a, as shown in figure 37, can assemble electro-motor 5.

At this moment, resolver 5h is contained in the connecting portion 5b from the state that opening 5k is projected into foreign side with the protrusion 5x of resolver housing 5u, by protrusion 5x and the opposed mode of motor terminal tm1～tm3 motor stator 5c is coupled in the framework 5a with this resolver housing 5u, when connecting portion 5b tongue and groove is combined in framework 5a, protrusion 5r at the motor terminal tm1 that makes motor stator 5c～tm3 engages with the engagement groove 5y of the protrusion 5x that is formed at resolver housing 5u, under extension 5s and the state that engagement groove 5z engages, carry out integrated.

Under this state, the length setting of extension 5s becomes: make the portion of terminal 5t of motor terminal tm1～tm3, with than the end face of mounting flange 5n a little by the end face coplane of the protrusion 5x of rear side.

By constituting electro-motor 5 with such arrangement of parts, can suppress the resolver stator 5v and the axial dislocation of resolver rotor 5w that cause because of the precision of assembly error, each parts and linear expansion factor difference etc., can prevent the accuracy of detection reduction.

In addition, on the outstanding end face of the output shaft 5f of electro-motor 5 from connecting portion, be formed with female splines (female ス プ ラ イ Application), when being assembled into electro-motor 5 on the reducing gearbox 4, only, just can form coupler by making this female splines and cooperating in that the male splines (male ス プ ラ イ Application) that forms on the worm shaft 11a of worm screw 11 is installed, therefore, man-hour, seldom and reliability was very high, so be fit to be applied in the electric power-assisted steering apparatus.

But, about spline between cooperation, if the unmatched words of phase place of their key tooth and keyway, just can not cooperate, when assembling electro-motor 5, connecting portion 5b along the circumferential direction is being pressed against it on worm shaft 11a in the rotation arbitrarily, till the phase matched between the spline, in the moment that can cooperate slightly, make connecting portion 5b rotation, so that the through hole of connecting portion 5b is consistent with the phase place of the screw of motor installation portion 17, then, need be pressed into up to the end face of connecting portion 5b with till the end face of motor installation portion 17 contacts.

When among the spring contact terminal 19i～19k that resolver terminal tr1～tr3 is inserted into control unit 19 described later, must avoid the disengaging between the spline.Therefore, in the present embodiment, it is long to set the length of fit between the spline for give prominence to than the end face from connecting portion 5b of resolver terminal tr1～tr3 length.

Thereby, can under the state that cooperates very shallowly between the spline, make connecting portion 5b rotation, make resolver terminal tr1～tr3 consistent with the phase place of the insertion mouth of spring contact terminal 19i～19k, as coupler, use spline, can omit the bunch that is used between resolver terminal tr1～tr3 and spring contact terminal 19i～19k, transmitting signal simultaneously.

In addition, as shown in figure 39, control unit 19 has: the body skin 19a of rectangular shape roughly, its stacked and in power module substrate, control basal plate etc. are housed, and be installed on the control unit installation portion 20 of reducing gearbox 4, cast by the good conductive materials such as for example aluminium of heat conductivity and to form, the side opposite with control unit installation portion 20 of this body skin 19a is open; With lid 19b, it seals the open end face of this body skin 19a.At this, between body skin 19a and lid 19b, be provided with not shown filler,, drop resistance dustproof to improve.Lid 19b is provided with and adjusts window 19c, needn't pull down the formation that lid 19b just can carry out the torque sensor signal treatment circuit of circuit substrate shape.As shown in figure 35, under the state before electro-motor 5 is assembled into reducing gearbox 4, under situation about control unit 19 being installed on the reducing gearbox 4,, not correctly adjusted by the influence ground of electro-motor by carrying out the correction of torque sensor signal circuit.After the torque sensor signal treatment circuit is proofreaied and correct, adjust window 19c by not shown sealant sealing.

The bottom that is installed on the seating plane 19d on the control unit installation portion 20 at body skin 19a, be equipped with spring contact terminal 19e～19h, when the external connection terminals 15c that inserts torque sensor 15～15f, spring contact terminal 19e～19h utilizes spring force to carry out clamping, and, on body skin 19a and end faces electro-motor 5 opposed sides, be equipped with: screw thread fixed terminal tc1～tc3, they contact with motor terminal tm1～tm3; With spring contact terminal 19i～19k, when the resolver terminal tr1 that inserts resolver 5h～tr3, spring contact terminal 19i～19k utilizes spring force to carry out clamping.

In addition, on the opposition side end face of the end face that is equipped with screw thread fixed terminal tc1～tc3 and spring contact terminal 19i～19k of body skin 19a, be equipped with terminals for power supplies 19m and ECU splicing ear 19n, for example (Controller Area Network: controller local area network) communication is connected with the control setup (ECU) of body side ECU splicing ear 19n by CAN.

And, as shown in figure 34, control unit 19, make seating plane 19d towards control unit installation portion 20 sides, make the thermal conduction rating height, have under the heat transfer sheet 23 and this seating plane 19d state of contact of otch with the opposed position of spring contact terminal 19e～19h, the lower surface that makes body skin 19a is from the direction contact guidance face vertical with control unit installation portion 20 22 time, be installed on the control unit installation portion 20 of reducing gearbox 4, thus, external connection terminals 15c～the 15f of torque sensor 15 is inserted among spring contact terminal 19e～19h, and is held by spring force.

Under this state,, as shown in figure 35, finish the installation of control unit 19 on control unit installation portion 20 by screw thread fixed housing body 19a and control unit installation portion 20.

Like this, only green phase for the control unit installation portion 20 of reducing gearbox 4 from vertical direction installation and control unit 19, just can finish the external connection terminals 15c～15f of torque sensor and being electrically connected of spring contact terminal 19e～19h, the lid 19b that does not take control unit 19 apart just can be assembled into control unit 19 on the reducing gearbox 4, therefore, can cut down man-hour, but also can omit the bunch that is used for the transfer torque sensor signal.

And, as shown in figure 35, under the state on the control unit installation portion 20 that control unit 19 is assembled in reducing gearbox 4, the motor installation portion 17 of the screw thread fixed terminal tc1～tc3 that forms on body skin 19a and spring contact terminal 19i～19k and reducing gearbox 4 is arranged side by side, becomes the state more outstanding a little than motor installation portion 17.

Under the assembled state of this control unit 19, as shown in figure 34, by electro-motor 5 being installed on the motor installation portion 17 of reducing gearbox 4, and make the axle center of its worm shaft 11a consistent with the axle center of electro-motor 5, and make motor terminal tm1～tm3 and resolver terminal tr1～tr3, opposed with screw thread fixed terminal tc1～tc3 and spring contact terminal 19i～19k respectively, the portion of terminal 5t of motor terminal tm1～tm3 contacts with screw thread fixed terminal tc1～tc3, and resolver terminal tr1～tr3 is inserted among spring contact terminal 19i～19k and is held.

Under this state, mounting flange 5n among the connecting portion 5b of bolt up motor installation portion 17 and electro-motor 5, and,, finish the assembling of electro-motor 5 on reducing gearbox 4 as shown in figure 33 by motor terminal tm1～tm3 screw thread is fixed on screw thread fixed terminal tc1～tc3.

Like this, only by with electro-motor 5 from the vertical direction of attachment face of the motor installation portion 17 of reducing gearbox 4, be installed on the motor installation portion 17 of reducing gearbox 4, motor terminal tm1～tm3 is contacted with screw thread fixed terminal tc1～tc3, just can direct connection motor terminal tm1～tm3 via bunch and screw thread fixed terminal tc1～tc3 between, and, owing to firmly and reliably contact and be electrically connected by screw shaft power, therefore, the distribution loss can be reduced, and the fluctuation of contact resistance can be suppressed.

In addition, because being bent to form from protrusion 5r, extension 5s and portion of terminal 5t, motor terminal tm1～tm3 is a plurality of sections, therefore, can prevent because of assembly error, each parts precision and the linear expansion factor difference etc. of electro-motor 5, and cause the screw thread fixed terminal tc1～tc3 of control unit 19 and the connecting portion of motor terminal tm1～tm3 and bus 5p are applied excessive stress with control unit 19.

And, motor terminal tm1～tm3 is configured in connecting portion 5b side with roughly circular bus, and this roughly circular bus connects the end that is wound on the motor coil on the motor stator 5c, therefore, motor terminal tm1～tm3 can be shortened, the distribution loss can be reduced.

Meanwhile, resolver terminal tr1～tr3 can be inserted in spring contact terminal 19i～19k and carry out clamping, just can direct connection resolver terminal tr1～tr3 by bunch and spring contact terminal 19i～19k between.

Below, the Assembly Action of above-mentioned embodiment is described.

At first, when assembling electric power-assisted steering apparatus 1, in the torque sensor incorporating section 16 of reducing gearbox 4, fixed configurations torque sensor 15 makes the front end edge spigot surface 22 of its external connection terminals 15c～15f prolong to the vehicle body rear.

Then, installation and control unit 19 on the control unit installation portion 20 of reducing gearbox 4.The installation of this control unit 19 is carried out in the following manner: make seating plane 19d towards control unit installation portion 20 sides, make under the high heat transfer sheet of thermal conduction rating 23 and this seating plane 19d state of contact, from the direction vertical with control unit installation portion 20, when making the lower surface contact guidance face 22 of body skin 19a, be installed on the control unit installation portion 20 from the direction vertical with the control unit installation portion 20 of reducing gearbox 4.Like this, with respect to the control unit installation portion 20 of reducing gearbox 4,, can easily between control unit 19 and control unit installation portion 20, sandwich the heat transfer sheet that is used to improve heat transmissibility thus from vertical direction assembling control unit 19.

In addition, when on the control unit installation portion 20 that control unit 19 is installed to reducing gearbox 4, meanwhile, external connection terminals 15c～the 15f of torque sensor 15 is inserted among the spring contact terminal 19e～19h of control unit 19, and be held by spring force, between the external connection terminals 15c～15f of torque sensor 15 and spring contact terminal 19e～19h, do not need to get involved bunch, can be electrically connected reliably.

At this moment, torque sensor 15 only is made of the moment of torsion detecting element, and in be contained in the reducing gearbox 4, because its signal processing circuit is assembled in the control unit 19, therefore, can easily carry out the correction of its signal processing circuit from the adjustment window 19c of lid 19b, and, owing to can before electro-motor is assembled into reducing gearbox 4, carry out the correction of signal processing circuit, therefore, can not be subjected to the influence ground of electro-motor 5 to carry out correct correction.

And, because being bent, the external connection terminals 15c～15f of torque sensor 15 is L word shape, therefore, can avoid the precision of assembly error, each parts and linear expansion factor difference etc. because of torque sensor 15 and control unit 19, and cause spring contact terminal 19e～19h and the external connection terminals 15c～15f of torque sensor 15 and the junction surface of torque sensor 15 to control unit 19, apply excessive stress, can improve durability.

Then, as mentioned above, make the electro-motor 5 of the state that is assembled into Figure 37, under the screw thread fixed terminal tc1～tc3 and the roughly opposed state of spring contact terminal 19i～19k of the central axial alignment of the center shaft of worm shaft 11a and electro-motor 5 and motor terminal tm1～tm3 and resolver terminal tr1～tr3 and control unit 19, near this motor installation portion 17, this motor installation portion 17 is adjacent with control unit 19 on reducing gearbox 4 from the direction vertical with the end face of motor installation portion 17.

At this moment, at first, make the female splines that is formed at output shaft 5f front end, contact, make electro-motor 5 rotations so that in both phase place unanimities, make female splines and male splines cooperate predetermined length with male splines on being formed at worm shaft 11a.Under this state, make the screw thread fixed terminal tc1～tc3 and the spring contact terminal 19i～19k of motor terminal tm1～tm3 and resolver terminal tr1～tr3 and control unit 19 opposed, and the mounting flange 5n of connecting portion 5b and the flange part of motor installation portion 17 are pressed into electro-motor 5 opposed to each other, thus, make the 5o of tongue and groove portion of the connecting portion 5b of electro-motor 5 carry out tongue and groove and combine, and the end face of connecting portion 5b is contacted with the end face of motor installation portion 17 with motor installation portion 17.

When becoming this state, at first, resolver terminal tr1～tr3 is inserted in the insertion mouth of spring contact terminal 19i～19k of control unit 19, and then the portion of terminal 5t of motor terminal tm1～tm3 contacts with the screw thread fixed terminal tc1～tc3 of control unit 19.

Under this state, the mounting flange 5n of bolt up connecting portion 5b and the flange part 17a of motor installation portion 17, and, the portion of terminal 5t of screw thread fixing motor terminal tm1～tm3 and the screw thread fixed terminal tc1～tc3 of control unit 19.

Like this, only by electro-motor 5 is installed on the motor installation portion 17 from the direction vertical with the end face of the motor installation portion 17 of reducing gearbox 4, just make the screw thread fixed terminal tc1～tc3 of motor terminal tm1～tm3 touch controls unit 19, and resolver terminal tr1～tr3 is inserted among the spring contact terminal 19i～19k of control unit 19, just both electrical connections can be carried out, their connection man-hour can be cut down.

At this moment, because motor terminal tm1～tm3 fixedly carries out with combining by screw thread of screw thread fixed terminal tc1～tc3, therefore, can be firmly and carry out both combinations reliably, suppress the fluctuation of contact resistance, and, the combination of resolver terminal tr1～tr3 and spring contact terminal 19i～19k also can be carried out reliably by spring force, and both needn't get involved bunch and directly be electrically connected, therefore, the distribution loss can be reduced, and the reduction of cost can be realized.

And, used brushless motor as electro-motor 5, therefore, the not loss that causes because of the contact resistance of brush, with omitted the bunch that is used for motor energising and combined, electric power-assisted steering apparatus can be applied in needs in the big Oversize vehicle that turns to augmented thrust, and this big augmented thrust that turns to is only all can not obtain with either party's low loss means.Be applied to shall not be applied to Oversize vehicle under the situation of medium-sized, compact car,, therefore, can make electro-motor 5 or control unit than present situation miniaturization more because loss is very little.

And, owing to control unit 19 is directly installed on the reducing gearbox 4 of big and face area also big being difficult for the becoming pyrotoxin of heat absorption capacity, therefore, the heating that is produced by control unit 19 can be directly delivered on the reducing gearbox 4 efficiently, can reduce and omit the radiating fin that is arranged in the control unit 19 as much as possible, can make the small-sized and light weight of structure of function unit 19.

Below, the 7th embodiment of the present invention is described with reference to Figure 40.

In the 7th embodiment, motor terminal is also the same with the resolver terminal, and it prolongs along the direction vertical with the end face of connecting portion.

Promptly, in the 7th embodiment, as shown in figure 40, portion of terminal 5t with the motor terminal tm1～tm3 in above-mentioned the 6th embodiment, be formed on the extended line of extension 5s, and it is the same with resolver terminal tr1～tr3, end face with respect to connecting portion 5b vertically prolongs, and therewith correspondingly, omits the screw thread fixed terminal tc1～tc3 of control unit 19, and the formation spring contact terminal ts1～ts3 in generation, in addition, have same structure with above-mentioned the 6th embodiment, for the cooresponding part of Figure 33～Figure 35, be marked with prosign, and omit its detailed description.

According to the 7th embodiment, when with electro-motor 5 from the vertical direction of end face of the motor installation portion 17 of reducing gearbox 4, when being installed on the motor installation portion 17, because motor terminal tm1～tm3 is the same with resolver terminal tr1～tr3, also be inserted among spring contact terminal ts1～ts3 and be held, therefore, the fixing operation of the screw thread that can omit the motor terminal tm1～tm3 in above-mentioned the 6th embodiment.In addition, owing to do not need the fixedly structure of bearing the tightening torque counter-force in the operation of screw thread, therefore, further cost-cutting.And, owing to not being mechanically fixing in order to tackle the motor terminal that big electric current has to thicken thickness of slab, owing to discharging the stress that produces because of the precision of assembly error, each parts and motor heating etc., so can improve reliability.

And, in the above-mentioned the 6th and the 7th embodiment, the situation that the present invention is applied in post assist type electric servo steering device is illustrated, but be not limited thereto, even be applied in miniature gears assist type or the rack assist type electric servo steering device, also can obtain and above-mentioned same effect.In the case, owing to be configured in the machinery space, therefore, as long as on the contact of control unit 19 and electro-motor 5, and on the contact of control unit 19 and torque sensor, be provided for waterproof and antisoiling sealing mechanism gets final product.

In addition, in the above-mentioned the 6th and the 7th embodiment,, the situation of having used screw thread fixed terminal and spring contact terminal is illustrated as the contact of motor terminal tm1～tm3 and control unit 19, but be not limited thereto, also can be electrically connected with at least one side of welding and soldering.

And, in the above-mentioned the 6th and the 7th embodiment, motor terminal tm1～tm3 is used screw thread fixed terminal and spring contact terminal, the resolver terminal tr1～tr3 only situation of applied spring contact terminal is illustrated, but also can mix respectively and use screw thread fixed terminal and spring contact terminal for motor terminal tm1～tm3 and resolver terminal tr1～tr3.

In addition, also can screw thread fixed terminal or spring contact terminal be set, motor terminal tm1～tm3 and resolver terminal tr1～tr3 be set in the control unit side in electro-motor 5 sides.

And, in the above-mentioned the 6th and the 7th embodiment, as electro-motor 5, situation to the motor rotor 5g that used surperficial magnetic type is illustrated, but be not limited thereto, also can use magnet baried type (IPM:Interior Permanent Magnet: brushless motor embedded permanent magnet), the brushless motor of other form such as induction motor.

In addition, in the above-mentioned the 6th and the 7th embodiment, to on the output shaft 5f of electro-motor 5, forming female splines, the situation that forms male splines on worm shaft 11a is illustrated, but also can become these inverse relationship, on the output shaft 5f of electro-motor 5, form male splines, on worm shaft 11a, form female splines, and also can replace spline fitted and use serration spline and cooperate.

And, when being assembled into electro-motor 5 on the reducing gearbox 4,, will cover on the terminal along the anchor clamps that radially draw of connecting portion 5b if under the state that cooperates very shallowly between the spline, then when spline fitted, can prevent terminal bends or breakage.

In addition, in the above-mentioned the 6th and the 7th embodiment, to the situation that control unit 19 is installed on the control unit installation portion 20 being illustrated, but also can omit heat transfer sheet 23 across heat transfer sheet 23.

And, in the above-mentioned the 6th and the 7th embodiment, the situation of the brushless motor of having used 3 phases is illustrated, but be not limited thereto, also can use 4 above mutually heterogeneous brushless motors, in the case, be the number of the corresponding number of phases as long as make motor terminal.Similarly,, also can export the 3 different phase resolver signals of phase place of 120 degree for resolver 5h, in the case, as long as make the resolver terminal comprise that excitation signal is provided with 4 pairs in being used in.

In addition, in the above-mentioned the 6th and the 7th embodiment, to only constituting torque sensor 15 with the moment of torsion detecting element, and situation about being contained in the control unit 19 in its signal processing circuit is illustrated, but be not limited thereto, also can be by moment of torsion detecting element 15a, 15b and signal processing circuit thereof constitute torque sensor 15, in reducing gearbox 4, interior dress moment of torsion detecting element 15a, 15b, and set and moment of torsion detecting element 15a, the signal processing circuit that 15b is electrically connected, in the case, under the state of reducing gearbox 4 monomers, just can the correcting signal treatment circuit, can not be subjected to the influence ground of electro-motor to carry out the correction of signal processing circuit.And, electro-motor 5 is assembled on the reducing gearbox 4 of the signal processing circuit correction of having finished torque sensor 15, then, can carry out being electrically connected between control unit 19 and the moment of torsion detecting element in the stage of having assembled control unit 19, and being electrically connected between control unit 19 and the electro-motor 5, can easily carry out assembling operation, can simplify assembling procedure and the precision of torque sensor is reduced.

The possibility of utilizing on the industry

By control unit is arranged on the reducing gearbox, the splicing ear of electro-motor can be directly electrically connected on the control unit, can make between control unit and the electro-motor to be electrically connected length the shortest, reduce sneaking into of electrical noise, and can make the wiring resistance minimum, reduce electrical loss, and owing between electro-motor and control unit, do not need to be provided with the motor wire harness, therefore, such electric power-assisted steering apparatus can be provided: the noise that radiates from the motor wire harness is few, can alleviate the influence to radio noise.

In addition, electro-motor and control unit are set up in parallel on reducing gearbox, and with the motor-side connecting portion outstanding be formed on electro-motor with control unit near and opposed position on, control unit with electro-motor near and opposed position on, form the cell side connecting portion that contacts with motor-side connecting portion face, therefore, such electric power-assisted steering apparatus can be provided: can by near and the motor-side connecting portion of face contact and cell side connecting portion carry out being connected between electro-motor and the control unit, make electrical connection length between the two be minimum, it is minimum making wiring resistance, and can prevent sneaking into of electrical noise reliably, and, do not need to form the big splicing ear of rigidity, and assembleability is improved.

And with before the worm shaft of Worm gear mechanism cooperates, the motor-side splicing ear does not overlap with control unit side splicing ear at the output shaft of electro-motor.Thereby, can provide such electric power-assisted steering apparatus: the phase matched that can easily carry out the worm shaft of the output shaft of electro-motor and Worm gear mechanism.

In addition, because making at least one side of motor-side splicing ear and cell side splicing ear is flexible structure, making the opposing party is rigid construction, by making a side elastic deformation takes place with both electrical connections, therefore, will the motor-side splicing ear and the substrate-side splicing ear be configured in high-precision position, not needing to make motor-side splicing ear and substrate-side splicing ear is flexible structure, therefore, can provide the electric power-assisted steering apparatus that can reduce manufacturing cost.

And, using under the situation of brushless motor as electro-motor, can provide such electric power-assisted steering apparatus: the not loss that causes because of the contact resistance of brush, can omit the bunch that is used for the motor energising, can produce the big augmented thrust that turns to, electric power-assisted steering apparatus can be applied in the Oversize vehicle.

Claims (17)

1. electric power-assisted steering apparatus, it has: Steering gear, steering shaft is housed in it, steering torque is passed to this steering shaft; Reducing gearbox, it is connected on this Steering gear; And electro-motor, it is passed to above-mentioned steering shaft by the speed reduction gearing in this reducing gearbox with power steering, it is characterized in that,

On above-mentioned reducing gearbox, be set side by side with above-mentioned electro-motor and control unit, above-mentioned control unit comprises the control basal plate that control circuit is installed, above-mentioned control circuit is used for the above-mentioned electro-motor of drive controlling, on above-mentioned control unit, directly be electrically connected with the splicing ear of above-mentioned electro-motor, and, be loaded on the splicing ear of the torque sensor in the above-mentioned reducing gearbox in directly being electrically connected with

Above-mentioned reducing gearbox has at least: the worm screw incorporating section, and it takes in the output shaft bonded assembly worm screw with above-mentioned electro-motor; The worm gear incorporating section, it is taken in and above-mentioned steering shaft bonded assembly worm gear; And torque sensor incorporating section, it is connected with above-mentioned worm gear incorporating section, be used to take in above-mentioned torque sensor, and be connected with Steering gear, peripheral part in above-mentioned worm screw incorporating section, worm gear incorporating section and torque sensor incorporating section is formed with the control unit installation portion that above-mentioned control unit is installed.

2. electric power-assisted steering apparatus according to claim 1 is characterized in that,

With the front end of above-mentioned torque sensor incorporating section, the contraction stopper section of the Steering gear during as crumple is installed in the endface position of the contraction stopper section side of the control unit on the above-mentioned control unit installation portion, is set to than shrinking the stopper section more by worm gear incorporating section side.

3. electric power-assisted steering apparatus according to claim 1 is characterized in that,

Above-mentioned electro-motor with above-mentioned control unit near and opposed position on, the motor-side connecting portion is at least to forming highlightedly with axial direction of intersecting, above-mentioned control unit with above-mentioned electro-motor near and opposed position on, be formed with the cell side connecting portion that contacts with said motor side connecting portion face.

4. electric power-assisted steering apparatus according to claim 3 is characterized in that,

Said motor side connecting portion and said units side connecting portion are made of the either party in splicing ear and the terminal base.

5. electric power-assisted steering apparatus according to claim 3 is characterized in that,

Said motor side connecting portion forms with the bus that brush or coil is carried out distribution in the inside of above-mentioned electro-motor.

6. electric power-assisted steering apparatus according to claim 5 is characterized in that,

Said motor side connecting portion and cell side connecting portion making under both face state of contact, are fixed by a kind of fastener in screw, bolt and the rivet.

7. electric power-assisted steering apparatus according to claim 3 is characterized in that,

Said motor side connecting portion and cell side connecting portion are fixed by a kind of welding means in fusion, spot welding, TIG (the inert-gas tungsten-arc welding-tungsten electrode atmosphere gas arc welding) welding.

8. electric power-assisted steering apparatus according to claim 3 is characterized in that,

Said motor side connecting portion and cell side connecting portion are made of the male type terminal and the gynetype terminal that can load and unload from the circumferencial direction of above-mentioned electro-motor.

9. electric power-assisted steering apparatus according to claim 6 is characterized in that,

The attachment face at above-mentioned reducing gearbox that the contact surface of said motor side connecting portion and cell side connecting portion is configured to above-mentioned electro-motor is same plane.

10. electric power-assisted steering apparatus according to claim 9 is characterized in that,

Said motor side connecting portion sees from the side and forms L word shape, and it is by forming along the axial board of above-mentioned electro-motor and from the outstanding board that the front end edge radial direction of this board prolongs.

11. electric power-assisted steering apparatus according to claim 3 is characterized in that,

Either party in said motor side connecting portion and the said units side connecting portion is made of the terminal clamp of the word of falling L shape, and this terminal clamp has: the radial direction board, and its outer peripheral face from above-mentioned electro-motor prolongs along radial direction; With axial board, its front end and axially parallel ground from this radial direction board prolongs,

The opposing party of said motor side connecting portion and cell side connecting portion is made of the terminal base with axial contact surface, and the face towards the outer peripheral face of electro-motor of this axial contact surface and above-mentioned axial board contacts.

12. electric power-assisted steering apparatus according to claim 3 is characterized in that,

Either party in said motor side connecting portion and the said units side connecting portion is formed with the terminal board that is installed in each flexible cable front end by the many flexible cables of deriving from peripheral part,

The opposing party in said motor side connecting portion and the said units side connecting portion is made of terminal base, this above-mentioned electro-motor in terminal base upper edge axially be formed with the contact surface that contacts with above-mentioned terminal board.

13. electric power-assisted steering apparatus according to claim 3 is characterized in that,

Either party in said motor side connecting portion and the said units side connecting portion is by forming with lower member: the cable guide part, be equipped with a plurality of radial direction boards that prolong along the radial direction of above-mentioned electro-motor in it; Many flexible cables, they are fixed in each radius direction plate portion of this cable guide part by the joint piece connection; And the terminal board, it is installed in the front end of this flexible cable,

The opposing party in said motor side connecting portion and the cell side connecting portion is made of terminal base, axially is formed with the contact surface that contacts with above-mentioned terminal board at this above-mentioned electro-motor in terminal base upper edge.

14. electric power-assisted steering apparatus according to claim 13 is characterized in that,

Above-mentioned cable guide part is formed with and makes many flexible cable non-conductive insulation gap walls.

15. electric power-assisted steering apparatus according to claim 12 is characterized in that,

Above-mentioned terminal base is formed with the insulation gap wall on the contact surface of the above-mentioned terminal board of contact, this insulation gap wall makes adjacent terminal board insulation.

16. electric power-assisted steering apparatus according to claim 10 is characterized in that,

Described electric power-assisted steering apparatus has protective case, and this protective case covers both under the state that said motor side connecting portion and said units side connecting portion couple together, and the height and position of this protective case is selected in below the height and position of above-mentioned control unit.

17. electric power-assisted steering apparatus according to claim 16 is characterized in that,

Above-mentioned control unit has synthetic resin system framework, this synthetic resin system framework with the splicing ear and the opposed position of the either party in the terminal base of above-mentioned electro-motor, installation board across being fixed on the above-mentioned reducing gearbox is formed with the opposing party in splicing ear and the terminal base.

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