JP2013067213A - Electronic circuit device of electric actuator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce noise by accommodating the connection part of a resolver 75 and a temperature sensor 78 of a motor unit 1 with a control unit 3 inside a mechanical/electrical connection chamber 9, and to prevent a control board 21 from receiving the external force.SOLUTION: The control unit 3 includes: a casing 18; a cover 19; a bus bar module 20; and the control board 21. The mechanical/electrical connection chamber 9 is structured between a housing 2 of the motor unit 1 and the casing 18. A connector 45 for a sensor s molded integrally with the bus bar module 20 and extends to the mechanical/electrical connection chamber 9 through an opening 70 sensor connector of the casing 18 to keep a connector 77 of the resolver 75 and the like connected. Terminals 46 of the connector 45 for a sensor are connected to the control board 21 penetrating the bus bar module 20.

Description

  The present invention relates to an electronic circuit device for an electric actuator used in an electric brake booster device for a vehicle.

  In recent years, an electric brake booster device in which the hydraulic pressure of a master cylinder is increased by using an electric actuator, for example, an electric motor, instead of a negative pressure type brake booster device using an internal combustion engine as a negative pressure source in a vehicle brake device has been proposed. ing.

  Patent Document 1 previously proposed by the present applicant discloses an electric brake booster device using a three-phase AC brushless motor that is concentrically centered around an input rod that moves in the axial direction in conjunction with a brake pedal as an actuator. An electronic circuit device including an inverter circuit that drives and controls the three-phase AC brushless motor, that is, a control unit is integrally mounted on the upper surface of the electric motor housing.

  The control unit includes a bus bar module in which power components are mounted and a plurality of bus bars are integrated with a synthetic resin material, and a control board formed of a printed wiring board disposed on the bus bar module. The three output terminals provided on the bus bar module are respectively connected to the three motor input terminals on the electric motor side in the space defined between the motor housing and the controller casing. .

JP 2010-132103 A

  In order to control the rotation of the three-phase AC brushless motor, a resolver for detecting the rotational position is indispensable, and generally, a temperature sensor for monitoring the temperature of the electric motor is also provided. Since signals of these sensors are to be input to the control board, they are not described in detail in the above-mentioned Patent Document 1, but conventionally, a resolver connector and a temperature sensor connector are provided on the control board. The connector at the tip of the harness that is mounted and extends from the resolver and the temperature sensor provided on the electric motor side is connected to the resolver connector and the temperature sensor connector on the control board.

  Therefore, since the resolver connector and the temperature sensor connector are provided on the control board having low strength and rigidity, stress is applied to the control board when the harness-side connector is detached, which is not preferable.

An electronic circuit device for an electric actuator according to the present invention includes:
A metal casing that is attached to the controller mounting portion of the housing of the electric actuator and forms an electromechanical connection space between the controller mounting portion and the bottom wall;
A bus bar module that is arranged in the casing and that is mounted with power components that drive the electric actuator, and in which a plurality of bus bars are integrated with a synthetic resin material,
An opening formed in the bottom wall of the casing;
A connector for a sensor that is formed integrally with the bus bar module in a shape protruding from the bus bar module having a plate shape, passes through the opening, and faces the electromechanical connection space;
The connector of the sensor attached to the electric actuator is configured to be connected to the sensor connector in the electromechanical connection space.

  According to the present invention, the bus bar module receives a force when the connector is attached and detached, and the stress acting on the control board made of the printed wiring board is suppressed.

The perspective view of the electric brake booster apparatus which assembled | attached the control unit to the housing of the motor unit. The exploded perspective view of the control unit of this electric brake booster device. The perspective view which shows the upper surface side of a bus-bar module. The expansion perspective view of the A section of FIG. The perspective view which shows the state which accumulated the control board on the upper surface of the bus-bar module. The perspective view which shows the lower surface side of a bus-bar module. The perspective view which shows the upper surface side of a casing. The perspective view which shows the lower surface side of a casing. The perspective view which shows the lower surface side of a casing in the state which combined the bus-bar module. Sectional drawing of the principal part along the cross section which passes along the connector for sensors. The expanded sectional view of the B section of FIG. Sectional drawing of the principal part in the state which assembled | attached the control unit to the housing of the electric motor.

  Hereinafter, an embodiment in which the present invention is applied to an electric brake booster device for a vehicle will be described in detail.

  FIG. 1 shows the configuration of the entire brake booster device in which the control unit 3 is assembled to the housing 2 of the motor unit 1, and FIG. 2 shows an exploded perspective view thereof.

  The motor unit 1 is attached to a bulk head (not shown) that partitions an engine room and a vehicle compartment of a vehicle body, and an input rod (not shown) that moves in the axial direction in conjunction with a brake pedal is on the right side of the figure. An electric motor (not shown) made up of a three-phase AC brushless motor that is located in the cylindrical portion 4 and is concentric with the cylindrical portion 4 is housed in the housing 2. Therefore, the housing 2 basically has a substantially cylindrical shape corresponding to the internal electric motor. A master cylinder 5 for supplying hydraulic pressure to the brake system is mounted at the center of the front end of the housing 2 that is supported in a cantilevered manner by the bulkhead. In accordance with the operated amount of the brake pedal, the electric motor can increase the pressure of the master cylinder 5.

  The housing 2 of the motor unit 1 is made of a metal made of, for example, aluminum alloy die-cast, and has a controller mounting portion on its upper surface (in other words, a part of the circumferential surface) as shown in FIG. 7 is provided. The controller mounting portion 7 includes an electromechanical connection chamber 9 surrounded by a peripheral wall portion 8 so as to form a substantially rectangular box shape whose upper surface is open, and a pair of flange portions 10 respectively provided on both sides thereof. A seal member 11 such as an O-ring that is continuous over the entire circumference of the electromechanical connection chamber 9 is disposed on the top of the peripheral wall portion 8. In the electromechanical connection chamber 9, as will be described later, three input terminals of the electric motor respectively connected to the three output terminals 15 on the control unit 3 side are arranged. A part of the peripheral wall 8 has a work hole 16 for connecting the output terminal 15 and the input terminal (screwing). The work hole 16 is finally closed by mounting a plug described later.

  As shown in FIG. 2, the control unit 3 includes a casing 18 made of a die-cast aluminum alloy or the like having a box shape with an upper surface opened, and a die-cast aluminum alloy or the like mounted in the upper surface opening of the casing 18. Or it consists of the cover 19 which consists of a sheet metal press-molded product, the bus bar module 20 accommodated in the inside which consists of these casings 18 and the cover 19, and the printed wiring board arrange | positioned on the upper surface of this bus bar module 20. The control board 21 is generally configured. The bus bar module 20 is fixed inside the casing 18 with a plurality of screws 22, and the cover 19 is covered with the casing 18 with a plurality of screws 23 so as to cover the bus bar module 20 and the control board 21. Is attached. The casing 18 is mounted on the controller mounting portion 7 with a plurality of screws 24 screwed into the flange portion 10 on the motor unit 1 side.

  3 to 6 show the bus bar module 20. The bus bar module 20 has a structure in which a plurality of bus bars 31 made of a copper plate or a brass plate through which a relatively large current for driving a three-phase AC motor flows is integrated into a plate shape with an insulating synthetic resin material. A main connector 26 having a flat cylindrical shape formed by integrating the power connector and the control signal connector is integrally formed on one side thereof. As shown in FIG. 3 and FIG. 5, the plurality of control signal terminals 27 reaching the control signal connector of the main connector 26 stand up individually without being connected to the bus bar 31, Are respectively connected to the control board 21. In addition, each bus bar 31 is provided with a large number of terminal pieces joined by welding or soldering to terminals of power components and noise countermeasure components mounted on the bus bar module 20, as shown in FIG. Each of the modules 20 protrudes upward from a synthetic resin portion forming a plate shape. The plurality of bus bars 31 are arranged three-dimensionally within the thickness of the bus bar module 20.

  As shown in an enlarged view in FIG. 4, a cylindrical support portion 32 for placing the control substrate 21 and the periphery of the control substrate 21 on the support portion 32 are provided at a plurality of locations on the periphery of the bus bar module 20. The locking claw 33 having a bulging tip is formed so that the control board 21 is connected to the bus bar as a so-called snap fit by the plurality of locking claws 33 arranged so as to sandwich the control board 21 from both sides. It is supported on the module 20. In other words, as shown in FIG. 5, the control board 21 is arranged so as to be superimposed on the bus bar module 20, and the contact with the terminal piece can be avoided between the upper surface of the bus bar module 20 by the plurality of support portions 32. Only a gap is secured. A part of the terminals extending upward from the bus bar module 20 is connected to the through hole of the control board 21 in the same manner as the control signal terminal 27.

  FIG. 6 shows the configuration of the bus bar module 20 on the lower surface side. As shown in FIG. 6, on the lower surface of the bus bar module 20, there are six semiconductor switching components that constitute an inverter circuit for driving a three-phase AC motor. An element (MOS-FET) 35, two relays 36 for cutting off / energizing current in the event of an abnormality, a plurality of electrolytic capacitors 37, a normal mode choke coil 38 and a common mode choke coil 39 for reducing noise in the circuit Power components such as a current detecting shunt resistor 40 and noise countermeasure components are mounted.

  An output terminal support portion 42 that rises in a wall shape from the lower surface of the bus bar module 20 is integrally formed at the center of the lower surface of the bus bar module 20, and there are three outputs of U, V, and W phases. Terminals 15 are provided in a line. These output terminals 15 protrude in the shape of a belt whose tip is rounded in an arc shape, and each has a hole for screwing at the tip.

  Similarly, a sensor connector 45 rising in a wall shape from the lower surface of the bus bar module 20 is integrally formed on one side of the lower surface of the bus bar module 20. The sensor connector 45 protrudes from the bus bar module 20 so as to form a cylindrical shape having an elongated rectangular cross section, and is partitioned into a resolver connector 45A and a temperature sensor connector 45B by an intermediate partition. In other words, in this embodiment, the resolver connector 45A and the temperature sensor connector 45B are integrated as one sensor connector 45. Each of the plurality of terminals 46 in the sensor connector 45 has a thin pin shape. However, as shown in FIG. 10, the upper surface of the bus bar module 20 penetrates the synthetic resin portion at the base of the sensor connector 45. Protrudes to the side. Each tip portion is connected to the control board 21 through a through hole of the control board 21 as shown in FIG. That is, although the terminals 46 of these sensor connectors 45 are supported by the bus bar module 20, they are not electrically connected to the bus bar 31 inside the bus bar module 20, and signals from a resolver and a temperature sensor to be described later are transmitted to the control board. 21 is directly transmitted.

  The output terminal support part 42 and the sensor connector 45 are arranged along the both sides of the region of the six semiconductor switching elements 35 arranged in a 2 × 3 shape, in other words, the six semiconductor switching elements 35 are connected to each other. It arrange | positions so that it may mutually oppose on both sides.

  FIGS. 10 and 11 show the sensor connector 45 and the cross-sectional shape of the tip thereof, respectively. As shown in these drawings, the opening edge of the sensor connector 45 having a rectangular cylindrical shape has In order to prevent the connector inserted here from being pulled out, a locking portion 48 slightly protruding toward the inner peripheral side of the opening edge is provided. Although this locking portion 48 is molded at the same time as the bus bar module 20 is molded, it is undercut with respect to the mold drawing direction. Therefore, in this embodiment, as shown in FIG. The locking portion 48 is formed by combining a mold 51 extending from the lower side of the drawing over the entire height and a mold 52 extending from the upper side of the drawing so as to form a tip opening edge portion of the sensor connector 45. Therefore, as a molded product, as shown in FIG. 10, the slit-shaped gap 53 by the mold 51 remains so as to penetrate the bus bar module 20 in the vertical direction. As is apparent from FIG. 10, only a part near the tip of the sensor connector 45 functions as an actual connector.

  7 and 8 show the casing 18 combined with the bus bar module 20 as a single unit. FIG. 7 shows an upper surface of the casing 18, that is, an inner configuration in which the bus bar module 20 is accommodated. The structure of the side which covers the lower surface of the casing 18, ie, the electromechanical connection chamber 9 of the motor unit 1, is shown. As shown in these drawings, screw holes 61 into which the screws 23 (see FIG. 2) for attaching the cover 19 described above are screwed are provided at four corners of the casing 18 having a substantially rectangular shape. Holes 62 through which the screws 24 (see FIG. 2) for fixing to the above-described motor unit 1 side are respectively provided at four locations protruding outward in an ear shape. In addition, a notch 63 into which the main connector 26 of the bus bar module 20 is fitted is provided on one side of the four side walls surrounding the periphery. A heat mass portion 64 having a thick rectangular block shape is formed at a central portion of the casing 18, specifically at a position corresponding to the region of the semiconductor switching element 35 of the bus bar module 20. The heat mass portion 64 is one step higher than the surrounding bottom wall surface, and its upper surface is close to the semiconductor switching element 35 that is heated. Note that a heat dissipation sheet made of an insulating material (not shown) may be attached to the upper surface of the heat mass portion 64 so as to be in direct contact with the semiconductor switching element 35. A large number of fins 65 are formed on the outer surface of the casing 18 in order to dissipate the heat received by the heat mass portion 64. A breathing hole 66 to which a breathing filter (not shown) is attached is opened on the side wall adjacent to the heat mass portion 64, and the space inside the control unit 3 communicates with the outside through the breathing hole 66. ing.

  The bus bar module 20 is accommodated in the casing 18 and fixed to the casing 18 by screws 22 (see FIG. 2) that are screwed into the plurality of bolt holes 67 shown in FIG. Here, the bus bar module 20 includes the output terminal support portion 42 and the sensor connector 45 that protrude like a standing wall as described above, but in the casing 18, the outer edge of the heat mass portion 64 is provided. An output terminal opening 69 corresponding to the output terminal support portion 42 of the bus bar module 20 is formed in a slit shape at the center portion of the bottom wall along the bottom wall, and is described above so as to penetrate one side portion of the heat mass portion 64. A sensor connector opening 70 corresponding to the sensor connector 45 of the bus bar module 20 is formed in a slit shape.

  Therefore, in the state where the bus bar module 20 is assembled to the casing 18, as shown in FIG. 9, the output terminal support portion 42 penetrates the output terminal opening 69 together with the output terminal 15, and the sensor connector. 45 penetrates through the sensor connector opening 70, and the respective leading ends protrude slightly from the lower surface of the casing 18.

  FIG. 12 shows a state in which the control unit 3 configured as described above is finally attached to the motor unit 1. As shown in the figure, the output terminal 15 protruding from the lower surface of the casing 18 and the sensor connector 45 is exposed in the electromechanical connection chamber 9 in the controller mounting portion 7. The electromechanical connection chamber 9 is an electromechanical connection space that is sealed from the outside by contacting the lower surface of the casing 18 to a sealing member 11 that surrounds the periphery, and three input terminals 71 of the electric motor are arranged in the interior thereof. The output terminals 15 are connected by screws 72 to the respective tip portions that are provided and bent into L-shapes. As described above, this screwing work is performed through the work hole 16 on the front surface of the electromechanical connection chamber 9, and the work hole 16 is finally closed by the plug 73. In addition, the sensor connector 45 has a front end surface which is a substantial connector insertion port facing the electromechanical connection chamber 9 downward, and a connector 77 at the front end of the harness 76 extending from the resolver 75 of the electric motor and a not shown. Connectors (not shown) at the tips of harnesses extending from the temperature sensor are respectively inserted into the sensor connectors 45. Therefore, as described above, the signal from the resolver 75 indicating the position of the rotor of the electric motor and the signal from the temperature sensor indicating the temperature state of the electric motor are input to the control board 21 via the terminals 46, respectively.

  The connector 77 and the like are inserted into the sensor connector 45 before the casing 18 is screwed to the motor unit 1 side. After the casing 18 is attached to the motor unit 1 side, the output terminal 15 is screwed. Is done.

  Thus, in the configuration of the above embodiment, the signal line from the resolver 75 and the temperature sensor (not shown) on the motor unit 1 side to the control board 21 of the control unit 3 is made of a metal casing (that is, the motor unit 1). Since the housing 2 and the casing 18) of the control unit 3 are completely surrounded and shielded, and the harness and connector portions are not routed outside the housing, noise associated with these signal lines is not generated. This is advantageous for reduction. In addition, since the connection portions such as the sensor connector 45 and the connector 77 are in a sealed space, the waterproof, dustproof, or chemical resistance is excellent.

  Further, the sensor connector 45 is firmly supported by the bus bar module 20 having high strength and rigidity together with the terminal 46, not the control board 21, so that the durability is enhanced and the external force when the connector 77 and the like are attached and detached is increased. Is received by the bus bar module 20, and the stress acting on the control board 21 made of a printed wiring board is suppressed. Therefore, damage to the control board 21 due to external force is suppressed.

  In the illustrated example, the resolver connector 45A and the temperature sensor connector 45B are integrated, but each has a separate and independent structure, and an opening corresponding to each is formed in the bottom wall of the casing 18. Also good. However, integrating the resolver connector 45 </ b> A and the temperature sensor connector 45 </ b> B as shown in the example is smaller as a whole, and is advantageous in securing strength and rigidity as the sensor connector 45.

  Further, in the above embodiment, the height of the sensor connector 45 is set so that the tip of the sensor connector 45 slightly protrudes from the lower surface of the casing 18, but as is apparent from FIG. As long as 77 and the like can be removed, the tip of the sensor connector 45 may be in the same surface as the lower surface of the casing 18 or in a position retreating from the lower surface of the casing 18.

  By the way, the sensor connector opening 70 provided on the bottom wall of the casing 18 for the sensor connector 45, together with the output terminal opening 69, serves as an air outlet for cooling the heat mass portion 64 of the casing 18. Also contribute. That is, the mechanical / electrical connection chamber 9 is slightly in communication with the interior of the motor unit 1, and pressure fluctuation occurs in the mechanical / electrical connection chamber 9 with the operation of the electric motor, so that air enters and exits through the breathing hole 66. At this time, air flows also in the sensor connector opening 70 and the output terminal opening 69, and these openings 69 and 70 are adjacent to the heat mass portion 64, so that heat is dissipated from the heat mass portion 64, that is, the heat mass. This can contribute to cooling of the portion 64.

  As mentioned above, although one Example which applied this invention to the electric brake booster apparatus of the vehicle was described, this invention is not restricted to this, About electric motors other than a three-phase alternating current electric motor, or electric actuators other than a motor Can be applied similarly.

DESCRIPTION OF SYMBOLS 1 ... Motor unit 2 ... Housing 3 ... Control unit 9 ... Electromechanical connection chamber 15 ... Output terminal 18 ... Casing 19 ... Cover 20 ... Bus bar module 21 ... Control board 42 ... Output terminal support part 45 ... Sensor connector 46 ... Terminal 69 ... Output terminal opening 70 ... Sensor connector opening 75 ... Resolver

Claims (2)

A metal casing that is attached to the controller mounting portion of the housing of the electric actuator and forms an electromechanical connection space between the controller mounting portion and the bottom wall;
A bus bar module that is arranged in the casing and that is mounted with power components that drive the electric actuator, and in which a plurality of bus bars are integrated with a synthetic resin material,
An opening formed in the bottom wall of the casing;
A connector for a sensor that is formed integrally with the bus bar module in a shape protruding from the bus bar module having a plate shape, passes through the opening, and faces the electromechanical connection space;
An electronic circuit device for an electric actuator, wherein a connector of a sensor attached to the electric actuator is connected to the sensor connector in the electromechanical connection space.   It has a control board arranged so as to overlap the bus bar module, and each terminal of the connector for the sensor penetrates the bus bar module and is connected to the control board without conducting with another bus bar. An electronic circuit device for an electric actuator according to claim 1.

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