JP2014159234A - Electric power steering apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric power steering apparatus which prevents invasion of solder, iron powder, gear abrasion powder, grease, etc. into a control unit and allows attaching the control unit to a deceleration gear box in a replaceable and freely removable way.SOLUTION: In a deceleration gear box 22 and an electric motor 14, a plurality of housing electric-motor-side connectors to be connected to a control unit 15 are formed, with their connection directions directed in the same direction. In the control unit 15, a plurality of control-unit-side connectors 56, 57, and 58 are formed, and the control-unit-side connectors are connected directly to the housing electric-motor-side connectors from the connection directions.

Description

The present invention relates to an electric power steering apparatus including an electric motor that applies a steering assist force to a steering system, and a control unit that controls an energization state of the electric motor according to a steering torque of the steering system.

As a conventional electric power steering apparatus, there is an apparatus that applies a steering assist torque to a steering system of a vehicle by decelerating the rotation of an electric motor with a gear box. In such an electric power steering device, there is known an electromechanical integrated device in which a control unit including a control board on which a control circuit for driving and controlling an electric motor is integrated into a gear box to reduce the size (for example, a patent Reference 1, 2, 3).

In the device of Patent Document 1, a control board on which a power module with heat generation is mounted is directly mounted on a control unit mounting surface provided in a gear box, and in the device of Patent Document 2, a through hole provided in a motor flange is provided. The control unit and the motor are connected via a motor terminal that passes therethrough. In the device of Patent Document 3, the control board of the control unit is housed in a housing recess provided in the gear box.

JP 2007-276741 A JP 2010-173466 A Japanese Patent No. 3922196

Since the devices of Patent Documents 1 to 3 sequentially assemble the control unit components in the gear box to form the control unit, the control unit components are soldered to the exposed control board during the assembly of the control unit components. When doing so, it is necessary to consider the effects of heat and short circuits on the control unit components due to solder scattering. In addition, it is necessary to devise measures to prevent iron powder, gear wear powder, grease, and the like that enter during assembly from entering the control unit components. In particular, in Patent Document 3, since a control board is provided inside the gear box, it is important to devise not to allow foreign matter to enter.

In addition, the devices of Patent Documents 1 to 3 cannot be replaced only when there is a malfunction in the control unit. Conversely, even if a problem occurs inside the gear box, the device must be replaced together with the control unit. . This is because the control board and the torque sensor or motor are connected by a semi-permanent method such as soldering or wire bonding. The present invention has been made paying attention to the unsolved problems of the above-described conventional example, and does not allow solder, iron powder, gear wear powder or grease to enter the control unit, and the control unit is installed in the reduction gear box. An object of the present invention is to provide an electric power steering device that can be detachably attached in a replaceable manner.

In order to achieve the above object, an electric power steering apparatus according to claim 1 of the present invention includes a steering shaft to which a steering torque is transmitted, and a steering assist force via a reduction mechanism in a reduction gear box. An electric motor for transmitting the control unit, a control unit including a control unit component including a control board for driving and controlling the electric motor, and a unit mounting surface provided on the outer periphery of the reduction gear box for mounting the control unit; And a plurality of housing / electric motor side connectors connected to the control unit are formed in the reduction gear box and the electric motor in a state in which the connection direction is directed in the same direction. Multiple control unit side connectors corresponding to the housing and electric motor side connectors Are, the plurality of control unit connector is characterized in that it is directly connected from the connecting direction to said plurality of housing the electric motor side connector.

According to a second aspect of the present invention, in the electric power steering apparatus according to the first aspect, the housing / electric motor side connector and the control unit side connector connected to each other are floating type connectors. According to a third aspect of the present invention, in the electric power steering apparatus according to the first or second aspect, a guide portion is provided for guiding a connection direction of the control unit side connector and the housing / electric motor side connector.

According to a fourth aspect of the present invention, in the electric power steering apparatus according to any one of the first to third aspects, the housing / electric motor side connector is a male terminal, and the control unit side connector is a female type. The control unit side connector is a floating type connector. According to a fifth aspect of the present invention, in the electric power steering apparatus according to the fourth aspect, the tip of the male terminal due to a shift in the connection direction and the control unit side connector at a position different from the female terminal. 5. The electric power steering apparatus according to claim 4, further comprising a male terminal protection unit for preventing a collision.

According to a sixth aspect of the present invention, in the electric power steering apparatus according to any one of the first to fifth aspects, the surface of the control unit mounted on the unit mounting surface is a heat radiating portion, and the housing When the reduction gear box and the control unit are fixed from a direction different from the connection direction of the electric motor side connector and the control unit side connector, the heat radiating portion comes into surface contact with the unit mounting surface.

Further, according to a seventh aspect of the present invention, there is provided the electric power steering device according to any one of the first to sixth aspects, wherein the plurality of housing / electric motor side connectors are housed in the reduction gear box. A torque sensor side connector connected to the motor, a rotation angle sensor side connector connected to a rotation angle sensor of the electric motor as a brushless motor, a power feeding connector for supplying power to the electric motor, and the plurality of control unit side connectors, The first connector directly connected to the torque sensor side connector, the second connector directly connected to the rotation angle sensor side connector, and the third connector directly connected to the power feeding connector.

According to the electric power steering apparatus according to the present invention, the housing and the electric motor side connector connected to the control unit are formed in the reduction gear box and the electric motor in a state where the connection direction is in the same direction. Is formed with a plurality of control unit side connectors respectively corresponding to a plurality of housing / electric motor side connectors, and the plurality of control unit side connectors are directly connected to the plurality of housing / electric motor side connectors from the connection direction described above. Therefore, the control unit incorporating the control unit components can be removably attached to the reduction gear box without solder, iron powder, gear wear powder or grease entering the unit.

It is a schematic block diagram which shows the electric power steering apparatus which concerns on this invention. It is a figure which shows the middle of the assembly of the electric power steering device of 1st Embodiment which concerns on this invention. It is a figure showing the important section of the electric power steering device of a 1st embodiment concerning the present invention. It is sectional drawing which shows the structure of the electric motor which comprises the electric power steering apparatus of 1st Embodiment which concerns on this invention. It is the figure which showed the structure of the housing and the electric motor side connector of the electric power steering apparatus of 1st Embodiment which concerns on this invention. It is the figure which showed the structure of the housing and electric motor side connector of FIG. 6 from the direction orthogonal to FIG. It is the figure which showed the structure of the control unit side connector of the electric power steering apparatus of 1st Embodiment which concerns on this invention. It is the figure which showed the principal part of the control unit side connector shown in FIG. It is a figure which shows the assembly middle of the electric power steering device of 2nd Embodiment which concerns on this invention. It is the figure which showed the electric power steering apparatus of 2nd Embodiment which concerns on this invention from the direction different from FIG. It is a figure which shows the state which mounted | wore the reduction gear box with the control unit in the electric power steering apparatus of 2nd Embodiment which concerns on this invention. It is a figure explaining the preferable form of the connector of this invention. It is a figure explaining the preferable form of the connector of this invention. It is a figure explaining the preferable form of the connector of this invention. It is a figure explaining the preferable form of the connector of this invention. It is a figure explaining the preferable form of the connector of this invention. It is a figure explaining the preferable form of the connector of this invention.

DESCRIPTION OF EMBODIMENTS Hereinafter, modes for carrying out the present invention (hereinafter referred to as embodiments) will be described in detail with reference to the drawings. FIG. 1 shows an outline of an electric power steering apparatus 1 according to the present invention. A steering mechanism 2 that is steered by a driver has a steering shaft 4 to which a steering force applied from the driver is transmitted to a steering wheel 3. have.

As shown in FIG. 4, the steering shaft 4 of the present embodiment is configured by connecting a torsion bar 4c between an input shaft 4a and an output shaft 4b. The steering shaft 4 has one end of the input shaft 4a connected to the steering wheel 3, and the other end connected to one end of the output shaft 4b via a torque sensor 5 as steering torque detecting means.

Returning to FIG. 1, the steering force transmitted to the output shaft 4 b is transmitted to the lower shaft 7 via the universal joint 6 and further transmitted to the pinion shaft 9 via the universal joint 8. The steering force transmitted to the pinion shaft 9 is transmitted to the tie rod 11 via the steering gear 10 to steer a steered wheel (not shown). Here, the steering gear 10 is configured in a rack and pinion type having a pinion 10a connected to the pinion shaft 9 and a rack 10b meshing with the pinion 10a, and the rotational motion transmitted to the pinion 10a is linearly moved by the rack 10b. It has been converted to movement.

A steering assist mechanism 12 that transmits a steering assist force to the output shaft 4b is connected to the output shaft 4b of the steering shaft 4. The steering assist mechanism 12 includes a reduction gear 13 connected to the output shaft 4 b and a brushless motor 14 that generates a steering assist force connected to the reduction gear 13. The brushless motor 14 is driven and controlled by the control unit 15. The control unit 15 includes a controller 16 and a motor drive circuit 17.

The controller 16 receives the steering torque applied to the steering wheel 3 detected by the torque sensor 5 and transmitted to the input shaft 4a, and the vehicle speed detection value output from the vehicle speed sensor 18 for detecting the vehicle speed. Is done. Then, the controller 16 calculates a steering assist command value with reference to a control map that stores the relationship between the steering torque and the steering assist command value using the vehicle speed detection value as a parameter, and calculates the calculated steering assist command value and the brushless motor 14. The motor current command value is calculated by performing feedback control based on the motor current flowing through the motor. The calculated motor current command value is supplied to a motor drive circuit 17 constituted by an inverter circuit, and the motor drive circuit 17 detects a motor current command value and a rotor rotation angle of a brushless motor 14 described later from a resolver 20. The motor drive current is formed based on the angle detection signal. Then, by supplying this motor drive current to the brushless motor 14, the brushless motor 14 generates a steering assist force corresponding to the steering assist command value. In addition, as a rotation angle sensor other than the resolver 20, a magnetic sensor using a Hall IC or an MR element can be used.

FIG.2 and FIG.3 is the perspective view which showed the electric power steering apparatus 1 of 1st Embodiment in the middle of an assembly. In the electric power steering apparatus 1 of the present embodiment, a reduction gear box 22 is connected to a steering column 21 that rotatably houses an input shaft 4 a of a steering shaft 4, and an axis L of the steering shaft 4 is connected to the reduction gear box 22. The brushless motor 14 and the control unit 15 are mounted in the orthogonal direction. Here, reference numeral 23 in FIG. 2 denotes a mounting bracket for attaching the steering shaft 4 to the vehicle body side member.

Below, the structure of the reduction gear box 22, the brushless motor 14, and the control unit 15 is demonstrated. The reduction gear box 22 is formed by die-casting, for example, any one of materials having high thermal conductivity, such as aluminum, aluminum alloy, magnesium, and magnesium alloy.

As shown in FIG. 4, the reduction gear box 22 includes a worm storage portion 25 that stores a worm 24 of a worm reduction gear connected to an output shaft (not shown) of the brushless motor 14, and a worm wheel that meshes with the worm 24. 26, a worm wheel storage portion 27 for storing 26, a torque sensor storage portion 28 for storing a torque sensor 5 integrally and coaxially connected to the vehicle rear side of the worm wheel storage portion 27, and an open end surface of the worm storage portion 25. A motor mounting flange 29 for mounting the brushless motor 14 formed on the outer periphery of the worm storage section 25 in the vicinity of the torque sensor storage section 28, and a planar unit mounting surface 30 perpendicular to the axis L of the steering shaft 4. It has. A pair of unit fixing surfaces 32 that are flush with the unit mounting surface 30 are formed at positions adjacent to the unit mounting surface 30, and screw holes are formed in these unit fixing surfaces 32.

As shown in FIG. 4, the torque sensor 5 includes a pair of detection coils 5 a and 5 b, and the pair of detection coils 5 a and 5 b magnetizes a twisted state between the input shaft 4 a and the output shaft 4 b of the steering shaft 4. Thus, the steering torque transmitted to the steering shaft 4 is detected. The torque sensor male terminals 5c to 5f are connected to the start and end of winding of the pair of detection coils 5a and 5b, and the terminal bases of these torque sensor male terminals 5c to 5f are firmly fixed. However, it protrudes to the outside from the opening provided in the torque sensor housing 28. These torque sensor male terminals 5c to 5f extend in parallel to the unit mounting surface 30 formed in the reduction gear box 22 (the outer periphery of the worm storage unit 25). Here, as shown in FIG. 3, the torque sensor male terminals 5 c to 5 f are orthogonal to a motor shaft M of a brushless motor 14 described later.

As shown in FIG. 3, the periphery of the torque sensor male terminals 5 c to 5 f is surrounded by a sensor terminal guide wall 31 that passes from the torque sensor 5 through the opening of the torque sensor storage portion 28. As shown in FIG. 5, the sensor terminal guide wall 31 is a channel-shaped member having an inner width dimension H and an inner height dimension T. As shown in FIG. 6, the torque sensor male terminal It protrudes outside from the tip of 5c-5f.

The brushless motor 14 is a three-phase motor. As shown in FIGS. 2 and 3, the motor case 40 is formed in a substantially cylindrical shape having one end opened and the other end closed, and one end of the motor case 40. A motor flange 41 is provided that is fixed to the opening edge and is fixed in contact with the motor mounting flange 29 of the reduction gear box 22. Although not shown, a substantially annular stator attached to the inner wall of the motor case 40, a rotor disposed on the inner peripheral side of the stator, and a resolver for detecting the rotation angle of the rotor, although not shown. 20 (see FIG. 1) is built in, and the stator has a stator core in which metal core plates are stacked, and a three-phase coil is wound on the inner peripheral side of the stator core via an insulator.

And as shown in FIG. 3, while the terminal of the coil of each phase is connected to the motor feed male terminal 43a-43c of the motor feed terminal block 42 formed in the motor flange 41, the sensor harness of the resolver 20 Are connected to the resolver male terminals 51 a to 51 d of the resolver terminal block 50 formed on the motor flange 41. The motor power supply terminal block 42 is formed so as to protrude from the surface of the motor flange 41 facing the reduction gear box 22, and motor power supply male terminals 43a to 43c whose terminal bases are firmly fixed to the motor power supply terminal block 42. Extends in parallel along the plane.

The motor power supply terminal block 42 is formed with a motor power supply guide wall 44 surrounding the motor power supply male terminals 43a to 43c. The motor power supply guide wall 44 has a shape similar to the sensor terminal guide wall 31 shown in FIGS. 5 and 6, has a channel shape, surrounds the motor power supply male terminals 43 a to 43 c, and It protrudes outside from the tips of the mold terminals 43a to 43c.

Similar to the motor power supply terminal block 42, the resolver terminal block 50 is formed to protrude from the surface of the motor flange 41 facing the reduction gear box 22, and the resolver terminal block 50 has a terminal base portion firmly fixed to the resolver terminal block 50. Male terminals 51a to 51d extend in parallel along the surface. The resolver terminal block 50 is also formed with a resolver terminal guide wall 52 surrounding the resolver male terminals 51a to 51d. The resolver terminal guide wall 52 is also similar in shape to the sensor terminal guide wall 31 shown in FIGS. 5 and 6, has a channel shape, surrounds the resolver male terminals 51 a to 51 d, and resolver male terminals Projecting outward from the tips of 51a to 51d.

When the motor flange 41 of the brushless motor 14 is fixed to the motor mounting flange 29 of the reduction gear box 22, as shown in FIG. 3, the motor feeding male terminals 43a to 43c and the resolver male terminals 51a to 51d are converted into torque sensors. It coincides with the direction in which the male terminals 5c to 5f extend (perpendicular to the motor shaft M of the brushless motor 14 and extends parallel to the unit mounting surface 30 of the reduction gear box 22). As shown in FIGS. 2 and 3, the control unit 15 closes the case main body 53 that houses the control board on which the controller 16 and the motor drive circuit 17 described above are mounted, and the opening of the case main body 53. And a cover 54.

As shown in FIG. 4, a heat radiating portion 55 made of a planar metal that can be in close contact with the flat unit mounting surface 30 of the reduction gear box 22 is formed on the lower surface of the case main body 53. As shown in FIG. 2, the control unit 15 has a pair of unit-side mounting portions 60 corresponding to the pair of unit fixing surfaces 32 when the heat radiating portion 55 of the case main body 53 contacts the unit mounting surface 30. The connection bolts (not shown) are screwed into the screw holes provided in the pair of unit fixing surfaces 32 from the bolt insertion holes provided in the pair of unit side mounting portions 60, so that the reduction gear box 22 The control unit 15 is mounted in a state where the heat radiating portion 55 is in close contact with the unit mounting surface 30.

Here, the direction in which the motor feeding male terminals 43a to 43c, the resolver male terminals 51a to 51d and the torque sensor male terminals 5c to 5f extend differs from the direction in which the control unit 15 is tightened by the connecting bolts. When a connector is used, excessive stress is applied to the terminals when the control unit 15 is fixed to the unit mounting surface 30, but the stress can be relieved with a floating type socket described later.

As shown in FIG. 2, a torque sensor socket 56 electrically connected to the controller 16, a motor power supply socket 57 and a resolver socket 58 electrically connected to the motor drive circuit 17 are provided on the side of the case body 53. , The heat radiating portion 55 is brought into contact with the unit mounting surface 30 of the reduction gear box 22, the torque sensor male terminals 5 c to 5 f are connected to the torque sensor socket 56, and the motor power supply socket 57 is supplied with motor power. The male terminals 43 a to 43 c are connected, and the resolver male terminals 51 a to 51 d are connected to the resolver socket 58.

7 and 8 show the torque sensor socket 56. FIG. The torque sensor socket 56 includes a socket body 56a made of a synthetic resin and a plurality of female terminals 59 embedded in the socket body 56a. The socket body 56 a has a substantially rectangular parallelepiped outer shape that can be fitted into the channel-shaped sensor terminal guide wall 31. That is, the socket body 56a has a width dimension H1 slightly smaller than the width dimension H inside the sensor terminal guide wall 31 and a height dimension T1 slightly smaller than the height dimension T inside the sensor terminal guide wall 31. It is.

As shown in FIG. 8, the female terminal 59 is a component made of a metal plate in which a cylindrical terminal portion 59a and a substantially U-shaped elastic deformation portion 59b are integrally formed. When the connecting direction of the torque sensor male terminals 5c to 5f and the cylindrical terminal portion 59a of the female terminal 59 is deviated, the torque sensor socket 56 has a pair of opposing flanges 59b1 of the elastic deformation portion 59b. , 59b2 swing and move the cylindrical terminal portion 59a to insert and engage the torque sensor male terminals 5c-5f. Thus, the torque sensor socket 56 is connected to the torque sensor male terminals 5c to 5f as floating type sockets.

Similarly to the torque sensor socket 56, the motor power supply socket 57 is also provided with a socket body made of synthetic resin and a female terminal 59 having substantially the same shape as FIG. 8 embedded in the socket body. When the connection direction between the feeding male terminals 43a to 43c and the cylindrical terminal portion 59a of the female terminal 59 is deviated, the pair of opposing flanges 59b1 and 59b2 of the elastically deforming portion 59b are swung so that the cylindrical terminal The motor power supply male terminals 43a to 43c are connected to the motor power supply male terminals 43a to 43c as floating type sockets that are engaged by inserting and engaging the motor power supply male terminals 43a to 43c by moving the portion 59a.

Further, the resolver socket 58, like the torque sensor socket 56, includes a socket body made of a synthetic resin and a female terminal 59 having substantially the same shape as that shown in FIG. When the connection direction between the mold terminals 51a to 51d and the cylindrical terminal portion 59a of the female terminal 59 is deviated, the pair of opposing flanges 59b1 and 59b2 of the elastically deforming portion 59b swings and the cylindrical terminal portion 59a. Are connected to the resolver male terminals 51a to 51d as floating type sockets which are inserted and engaged with the resolver male terminals 51a to 51d.

Next, the operation of mounting the control unit 15 on the reduction gear box 22 will be described. In the brushless motor 14, the motor flange 41 is fixed to the motor mounting flange 29 of the reduction gear box 22, and the motor power supply terminal block 42 and the resolver terminal block 50 protrude from the surface of the motor flange 41 facing the reduction gear box 22. The motor power supply terminal block 42 to the motor power supply male terminals 43a to 43c and the resolver terminal block 50 to the resolver male terminals 51a to 51d are formed in the same direction as the torque sensor male terminals 5c to 5f. It extends parallel to the mounting surface 30.

Then, the heat radiating portion 55 of the control unit 15 is placed on the unit mounting surface 30 of the reduction gear box 22 so that the pair of unit side mounting portions 60 of the control unit 15 correspond to the unit fixing surface 32 of the reduction gear box 22. The control unit 15 on the mounting surface 30 is slid toward the torque sensor storage unit 28. Then, the torque sensor socket 56, the motor power supply socket 57, and the resolver socket 58 of the control unit 15 that is slid are fitted into the sensor terminal guide wall 31, the motor power supply guide wall 44, and the resolver terminal guide wall 52, and then the torque. Connector connection is made to the sensor male terminals 5c to 5f, the motor feeding male terminals 43a to 43c, and the resolver male terminals 51a to 51d.

At this time, the connection directions of the torque sensor socket 56, the motor power supply socket 57, and the resolver socket 58 are shifted with respect to the torque sensor male terminals 5c to 5f, the motor power supply male terminals 43a to 43c, and the resolver male terminals 51a to 51d. Even if the torque sensor socket 56, the motor power supply socket 57, and the reso lever socket 58 are formed as floating type sockets, the torque sensor male terminals 5c to 5f and the motor power supply male are securely connected. Connector connection between the mold terminals 43a to 43c and the resolver male terminals 51a to 51d is performed. Further, as shown in FIG. 6, the sensor terminal guide wall 31 protrudes outward from the tips of the torque sensor male terminals 5c to 5f, and the torque sensor male terminals 5c to 5f are connected to the torque sensor in a state where the connection direction is shifted. Even if the socket 56 is directed, the sensor terminal guide wall 31 prevents the torque sensor socket 56 and the torque sensor male terminals 5c to 5f from colliding with each other.

Further, the motor power supply guide wall 44 protrudes to the outside from the tips of the motor power supply male terminals 43a to 43c, and even if the motor power supply socket 57 is directed to the motor power supply male terminals 43a to 43c in a state where the connection direction is deviated. The motor power supply guide wall 44 prevents the motor power supply socket 57 and the motor power supply male terminals 43a to 43c from colliding with each other. Furthermore, the resolver terminal guide wall 52 protrudes outward from the tips of the resolver male terminals 51a to 51d, and even if the resolver socket 58 is directed to the resolver male terminals 51a to 51d in a state where the connection direction is shifted, The guide wall 52 prevents a collision between the resolver socket 58 and the resolver male terminals 51a to 51d.

The torque sensor socket 56, the motor power supply socket 57, and the resolver socket 58 of the control unit 15 are connected to the torque sensor male terminals 5c to 5f, the motor power supply male terminals 43a to 43c, and the resolver male terminals 51a to 51d. Thereafter, the unit fixing surface 32 of the reduction gear box 22 and the pair of unit side mounting portions 60 of the control unit 15 corresponding to each other are fixed via connecting bolts. The connecting direction of the connecting bolts fixed to the reduction gear box 22 and the control unit 15 is a direction orthogonal to the connector connecting direction described above, and the torque sensor socket 56, the motor power supply socket 57, the resolver socket 58 and the torque sensor male type. The terminals 5c to 5f, the motor feed male terminals 43a to 43c, and the resolver male terminals 51a to 51d are reliably prevented from coming off, and the unit mounting surface 30 of the reduction gear box 22 and the heat radiating portion 55 of the control unit 15 are in close contact with each other. To do.

Next, the effect of the electric power steering apparatus 1 of this embodiment is described. In the present embodiment, torque sensor male terminals 5c to 5f provided on the reduction gear box 22, motor feed male terminals 43a to 43c and resolver male terminals 51a to 51d provided on the motor flange 41 of the brushless motor 14 are provided. In the position surrounding the unit mounting surface 30 of the reduction gear box 22, the terminals extend in parallel to the unit mounting surface 30 with the direction in which the terminals extend as the same direction, and protrudes to the outside. Therefore, the control unit 15 is brought into contact with the unit mounting surface 30 of the reduction gear box 22 so that the mounting position of the control unit 15 (the pair of unit side mounting portions 60 of the control unit 15 is fixed to the unit fixing surface 32 of the reduction gear box 22). The torque sensor socket 56 provided on the side surface of the control unit 15 is connected to the torque sensor male terminals 5c to 5f, and the motor power supply socket 57 is connected to the motor power supply male terminals 43a to 43c. The connector is connected, and the resolver socket 58 is connected to the resolver male terminals 51a to 51d. As a result, the control unit 15 can be easily connected to the connector.

Further, since the control unit 15 is a unit type in which most of the controller 16 and the motor drive circuit 17 are covered with the case main body 53 and the cover 54, foreign matter or the like does not enter when assembled to the reduction gear box 22. The reliability of the control unit 15 can be improved. Also, the defective control unit 15 can be easily replaced from the reduction gear box 22.

The torque sensor socket 56, the motor power supply socket 57, and the resolver socket 58 are connected to the torque sensor male terminals 5c to 5f, the motor power supply male terminals 43a to 43c, and the resolver male terminals 51a to 51d, respectively. Since it is formed as a floating type socket that absorbs the displacement in the direction, even if the control unit 15 is brought into contact with the unit mounting surface 30 with a slight displacement, the torque sensor male terminal 5c˜ 5f, the motor feeding male terminals 43a to 43c and the resolver male terminals 51a to 51d can be reliably connected.

In addition, the male and female structures of the terminals on the reduction gear box 22 and the brushless motor 14 side and the terminals on the control unit 15 side can be reversed, but in this embodiment, the processing is simple and easy to process. Since the sockets (torque sensor socket, motor power supply socket 57 and resolver socket 58) are formed in the control unit 15, the cost can be reduced.

In addition, it is possible to provide a sensing component such as the torque sensor 5 and resolver 20 with an error absorbing mechanism that absorbs the displacement in the connection direction, and a mespin (socket). In this case, both simplicity and compactness can be achieved. You will lose. For this reason, it is preferable to provide a male terminal in the sensing component. In addition, a floating mechanism can be provided in the male pin (male terminal), but if the root of the OSPON is not firmly fixed, the pin may be bent. For this reason, it is desirable that the male pin is firmly fixed.

Furthermore, the torque sensor socket 56, the motor power supply socket 57, and the resolver socket 58 in which the displacement in the connection direction has occurred correspond to the torque sensor male terminals 5c to 5f, the motor power supply male terminals 43a to 43c, and the resolver male terminals, respectively. Even if it moves toward 51a-51d, torque sensor socket 56, motor feeding socket 57, and resolver socket 58 are torque sensor male terminals 5c-5f, motor feeding male terminals 43a-43c, and resolver male terminals 51a-51d. Without colliding with the tip of the sensor, but it collides with the sensor terminal guide wall 31, the motor power supply guide wall 44 and the resolver terminal guide wall 52, so that the torque sensor male terminals 5c-5f and motor power supply male terminals 43a- 43c and the ends of the resolver male terminals 51a to 51d are protected. Can.

The sensor terminal guide wall 31, the motor power supply guide wall 44, and the resolver terminal guide wall 52 are fitted into the torque sensor socket 56, the motor power supply socket 57, and the resolver socket 58, so that the torque sensor socket 56, the motor power supply socket 57, and The resolver socket 58 can guide the torque sensor male terminals 5c to 5f, the motor power feeding male terminals 43a to 43c, and the resolver male terminals 51a to 51d to appropriate connection positions. Therefore, since the male terminal is not inserted into the female terminal in a state in which the male terminal is broken, and the connector is securely joined, a highly reliable connection structure can be obtained.

Furthermore, when the pair of unit side mounting portions 60 of the control unit 15 corresponding to the unit fixing surface 32 of the reduction gear box 22 are fixed with connecting bolts, the control unit 15 is fixed to the planar unit fixing surface 32 of the reduction gear box 22. Since the heat radiation part 55 having a planar shape is in close contact and the heat generated in the control unit is released to the outside through the reduction gear box 22 and the cooling effect is enhanced, a special cooling structure such as a cooling fin is not provided in the control unit. That's it.

Next, what is shown in FIG. 9 to FIG. 11 is a perspective view showing the electric power steering apparatus 1 of the second embodiment during assembly. In addition, the same code | symbol is attached | subjected to the same component as the electric power steering apparatus 1 of 1st Embodiment shown in FIGS. 2-8, and description is abbreviate | omitted. As shown in FIG. 9, the electric power steering apparatus 1 of the present embodiment has a flat unit mounting surface 69 perpendicular to the axis L of the steering shaft 4 on the outer periphery of the worm storage portion 25 in the vicinity of the torque sensor storage portion 28. Is formed.

Further, as shown in FIG. 10, torque sensor male terminals 5 c to 5 f connected to the start and end of winding of the pair of detection coils 5 a and 5 b of the torque sensor 5 are provided in the torque sensor housing portion 28. Protrudes from the outside. These torque sensor male terminals 5 c to 5 f are parallel to the unit mounting surface 69 described above and extend in a direction along the motor axis M of the brushless motor 14.

A sensor terminal guide portion 61 that protrudes forward from the tip of the torque sensor male terminals 5 c to 5 f is formed around the opening provided in the torque sensor housing portion 28. Further, motor feed male terminals 43a to 43c are arranged in an opening 62 formed in the motor flange 41 of the brushless motor 14, and the motor feed male terminals 43a to 43c extend in a direction along the motor axis M. doing. A motor power supply guide portion 63 is formed around the opening 62 and protrudes to the outside from the tips of the motor power supply male terminals 43a to 43c.

An opening 64 is formed at a different position with respect to the opening 62 of the motor flange 41, and resolver male terminals 51 a to 51 d are arranged extending in the direction along the motor axis M in the opening 64. Yes. A step-shaped resolver terminal guide portion 65 located around the opening 64 is formed in the motor mounting flange 29 of the reduction gear box 22 fixed to the motor flange 41.

As shown in FIG. 9, a torque sensor socket 66, a motor power supply socket 67, and a resolver socket 68 are formed on the side of the control unit 15. When the heat radiating portion 55 of the control unit 15 is placed on the unit mounting surface 69 of the reduction gear box 22 and the control unit 15 is slid in the direction along the motor axis M of the brushless motor 14, the torque sensor socket 66 has a torque sensor. The male terminals 5 c to 5 f are connected to the connector, the motor power supply socket 67 is connected to the motor power supply male terminals 43 a to 43 c, and the resolver socket 68 is connected to the resolver male terminals 51 a to 51 d.

The torque sensor socket 66, the motor power supply socket 67, and the resolver socket 68 are similar to the torque sensor socket 56, the motor power supply socket 57, and the resolver socket 58 shown in the first embodiment, and the torque sensor male terminals 5c to 5c to which the torque sensor socket 66, 5f, formed as a floating type socket that absorbs the displacement in the connecting direction with respect to the motor feeding male terminals 43a to 43c and the resolver male terminals 51a to 51d. Therefore, in this embodiment, the control unit 15 can be mounted on the reduction gear box 22 without intruding iron powder, gear wear powder, grease, or the like inside the unit, and the defective control unit 15 can be easily installed. The reduction gear box 22 can be replaced.

The torque sensor socket 66, the motor power supply socket 67, and the resolver socket 68 are connected to the torque sensor male terminals 5c to 5f, the motor power supply male terminals 43a to 43c, and the resolver male terminals 51a to 51d, respectively. Since it is formed as a floating type socket that absorbs the deviation of the direction, even if the control unit 15 is brought into contact with the unit mounting surface 69 with a slight positional deviation, the torque sensor male terminals 5c-5f Thus, it is possible to reliably connect the motor feeding male terminals 43a to 43c and the resolver male terminals 51a to 51d.

Further, in the brushless motor 14 of the present embodiment, the motor feeding male terminals 43a to 43c and the resolver male terminals 51a to 51d extend in the direction along the motor axis M, and the shapes of the terminals and connectors are simplified. Cost reduction of the brushless motor 14 can be achieved. Motor feeding male terminals 43 a to 43 c are arranged in an opening 62 formed in the motor flange 41, and these motor feeding male terminals 43 a to 43 c extend in a direction along the motor axis M. A motor power supply guide portion 63 is formed around the opening 62 and protrudes to the outside from the tips of the motor power supply male terminals 43a to 43c.

An opening 64 is formed at a different position with respect to the opening 62 of the motor flange 41, and resolver male terminals 51 a to 51 d are arranged extending in the direction along the motor axis M in the opening 64. Yes. A step-shaped resolver terminal guide portion 65 located around the opening 64 is formed in the motor mounting flange 29 of the reduction gear box 22 fixed to the motor flange 41.

Even if the torque sensor socket 66 in which the displacement in the connection direction has occurred moves toward the torque sensor male terminals 5c to 5f, before the torque sensor socket 66 and the tip of the torque sensor male terminals 5c to 5f collide. Further, since the torque sensor socket 66 and the sensor terminal guide portion 61 collide with each other, it is possible to protect the tips of the torque sensor male terminals 5c to 5f due to a shift in the connection direction.

Further, even if the motor feeding socket 67 in which the displacement in the connection direction has occurred moves toward the motor feeding male terminals 43a to 43c, before the motor feeding socket 67 collides with the tips of the motor feeding male terminals 43a to 43c. In addition, since the motor power supply socket 67 and the motor power supply guide portion 63 collide with each other, it is possible to protect the tips of the motor power supply male terminals 43a to 43c due to a shift in the connection direction.

Furthermore, even if the resolver socket 68 in which the displacement in the connection direction has occurred moves toward the resolver male terminals 51a to 51d, before the resolver socket 68 and the tip of the resolver male terminals 51a to 51d collide, Since 68 and the resolver terminal guide part 65 collide, the front-end | tip of the resolver male type | mold terminals 51a-51d by the shift | offset | difference of a connection direction can be performed.

The reduction gear housing of the present invention corresponds to the reduction gear box 22, and the housing / electric motor side connector of the present invention includes torque sensor male terminals 5c to 5f, motor power supply male terminals 43a to 43c, and resolver male terminals 51a. To 51d, the control unit side connector of the present invention corresponds to the torque sensor sockets 56, 66, the motor power supply sockets 57, 67, and the resolver sockets 58, 68. Further, the plurality of control unit side connectors of the present invention are directly connected to the plurality of housing / electric motor side connectors from the connection direction, which means that the control unit side connector and the housing / electric motor side facing each other in the connection direction It is said that one of the connectors is a male connector and the other is a female connector and is connected without a harness or the like. The rotation angle sensor of the present invention corresponds to the resolver 20, and the guide portion of the present invention is the sensor terminal guide wall 31, the motor power supply guide wall 44, the resolver terminal guide wall 52, the sensor terminal guide portion 61, and the motor power supply guide portion 63. Corresponding to the resolver terminal guide part 65, the male terminal protection part of the present invention has a sensor terminal guide wall 31, a motor power supply guide wall 44, a resolver terminal guide wall 52, a sensor terminal guide part 61 for each male terminal. , Corresponding to the structure in which the motor power supply guide portion 63 and the resolver terminal guide portion 65 protrude, the torque sensor side connector of the present invention corresponds to the torque sensor male terminals 5c to 5f, and the resolver side connector of the present invention is the resolver male. Corresponding to the mold terminals 51a to 51d, the power feeding connector of the present invention corresponds to the motor power feeding male terminals 43a to 43c, and the first connector of the present invention. There torque sensor socket 56 and 66, the second connector corresponds to the resolver socket 58, 68 of the present invention, the third connector of the present invention corresponds to the motor power supply socket 57 and 67.

Next, the preferable form of the connector used for this invention is described. As described above, the connector of the present invention has been described as connecting the torque sensor terminal, connecting the motor power supply terminal, and connecting the resolver signal. In addition to these connections, the present invention can be applied to various electrical connection portions in the electric power steering apparatus.

In other words, a preferred form of the connector used in the present invention is a connector that includes one or a plurality of terminals and a connector housing that holds the terminals, and is attached to a board, and the terminals are electrically connected to the board. The connector housing has an attachment portion for being attached to the board by a fixing means, and at least a connector. A part of the housing is attached so as to protrude in the horizontal direction from the substrate. Furthermore, it is preferable that the part connected with the said other party terminal among the said terminals exists in the position shifted | deviated to the perpendicular direction rather than the horizontal surface of the said board | substrate. Here, as the fixing means, it is possible to use various fixing means such as bolts and nuts, screws that are provided with screw holes in the substrate or mounting portion, screws, adhesives, welding and welding, and the like. it can. In consideration of long-term fixing stability and assembly (mounting), screwing is preferable. Moreover, when the said terminal forms a female connector, it is preferable to set it as a floating type connector.

In the connector used in the present invention, by adopting the above preferred form, the degree of freedom in designing the fixed position of the control unit in the electric power steering apparatus is improved, so that more efficient and rational arrangement can be achieved. can do. In particular, since it can be arranged with a margin in the input shaft direction (axial direction), for example, it can contribute to securing an EA stroke (collision safety stroke).

Hereinafter, with reference to the drawings, a three-terminal female connector will be described as a specific example of a preferred form of the connector of the present invention. However, the preferred form of the connector is not limited to a three-terminal or female connector. Furthermore, it can be used in combination with the forms exemplified below.

FIG. 12 is a diagram illustrating the floating type connector 100 and shows a state where it is mounted on the board 200. The connector 100 has a connector housing 101. The connector housing 101 is made of, for example, a synthetic resin. The connector housing 101 has an attachment portion 102 for being fixed to the substrate 200 using a fixing means. In the case of the connector 100, the attachment surface 104 and the surface 201 of the substrate 200 are formed by screws (not shown) by the attachment holes 103 provided in the attachment portion 102 and screw holes (not shown) provided in the substrate 200. And are fixed so that they are in close contact with each other. As a fixing means, it is possible to use means such as a bolt-nut method, rivet joining, pin joining, snap fitting, press-fitting, adhesion, welding and welding in addition to screws.

A terminal group is accommodated in the connector housing 101. In the form shown in FIG. 12, terminals 111a to 111d forming the first terminal group, terminals 112a to 112d forming the second terminal group, and terminals 113a to 113d forming the third terminal group are accommodated. ing. The terminals 111a to 113d have end portions 111e, 111f, 111g, 111h, 112e, 112f, 112g, 112h, 113e, 113f, 113g, and 113h, respectively. These end portions 111e to 113f are electrically connected to a wiring portion (not shown) provided on the surface 201 of the substrate 200 by connecting means such as solder. For example, when the end portions 111e to 113h and the wiring portion are connected by solder, the DIP method can be adopted, but the reflow method can be preferably used. In particular, since the mounting portion 102 of the connector 100 and the board 200 can be fixed in advance by the fixing means, the position of the connector 100, which is a relatively large component, does not shift even by the reflow method, and is inconvenient for electrical connection. Does not occur.

Here, the connector 100 is attached to the board 200 in close contact (close contact). Therefore, for example, the control unit having a connector can be downsized. Furthermore, it is attached so that at least a part of the connector housing protrudes from the horizontal end face of the substrate 200. Therefore, the protruding portion of the connector housing 101 serves as a guide portion when connected to the mating connector (not shown), and can be easily connected. Further, the method orthogonal to the surface 201 of the substrate 200 is configured such that the position can be freely set by adjusting the position of the mounting portion 102 in the connector housing 101 or the like. Therefore, not only the position of the connector 100 but also, for example, the degree of freedom in designing the control unit having the connector, and further, the degree of freedom in designing the fixed position of the control unit in the electric power steering apparatus are improved.・ A reasonable arrangement can be made. In particular, since it can be arranged with a margin in the input shaft direction (axial direction), for example, it can contribute to securing an EA stroke (collision safety stroke).

FIG. 13 is a diagram for explaining a connector 300 having a fitting portion for connection with a counterpart terminal (not shown). 13A is a perspective view of the side connected to the mating terminal, FIG. 13B is a perspective view of the board side, and FIG. 13C is for explaining the internal configuration of the connector 300. The cross section of the connector 300 is shown mechanically. The connector 100 of the form shown in FIG. 13 accommodates the first to third terminal groups T in the connector housing 301 in the same manner as the connector 100 shown in FIG. The connector housing opening 305 accommodates a fitting housing 320 having three insertion portions 321, 322, and 323 for fitting with the mating terminal. The method of attaching to the substrate is the same as that shown in FIG.

FIG. 13C mechanically shows a cross section in the insertion direction of the mating terminal of the connector 300. A portion of the terminal 311a extending into the connector housing 301 extends into the fitting housing 320 through two U-shaped bent portions 333 and 334. Similarly, the portion of the terminal 311 b that extends into the connector housing 301 also extends into the fitting housing 320 through two U-shaped bent portions 335 and 336. Opposing curved portions 331 and 332 are formed on the terminals 311 a and 311 b extending inside the fitting housing 320, and the terminals 311 a and 311 b are in contact with each other at a portion corresponding to the opening of the insertion portion 321. Since the terminals 311a and 311b are formed of a copper alloy or the like, the terminals 311a and 311b can be elastically deformed by providing a bent portion. The mating terminal inserted from the insertion portion 321 is connected to the bending portion 331 and the bending portion 332. It can hold | maintain with an elastic force between and can maintain an electrical contact. By providing the fitting housing, connection with the mating terminal is facilitated. Other functions and effects are the same as those shown in FIG.

FIGS. 14-17 demonstrates another form of the connector used for this invention. The connector shown in the figure includes an attachment portion similar to the connector 100 shown in FIG. Moreover, since the basic structure and the effect are the same as the form shown in FIG. 12, description is abbreviate | omitted about the overlapping part.

FIGS. 14A and 14B are perspective views of the connector 400 as viewed from the board side, in which the viewpoint is changed in the vertical direction of the board (direction perpendicular to the horizontal plane). In the connector 400, terminals 411a and 411b (upper terminals) constituting a group of terminal portions are united at a portion reaching the end portion 411e. The lower terminal of the first group has the same structure. The same applies to the second group of terminals and the third group of terminals. As a result, the surface area of the end portion 411e, which is a connection portion with the substrate, can be increased. For example, the strength of the connection by solder or the like increases, so that a more stable connection can be achieved.

15A and 15B are perspective views of the connector 600 as seen in FIGS. 14A and 14B. In the connector 600, the structure of terminals 611a, 611b, and 611c forming a group of terminal portions is different from that shown in FIG. That is, among the group of terminals, the upper terminal 611c is arranged between the lower terminals 611a and 611b. The same applies to the other terminal groups. As a result, even if the end portions 611e to 611g, which are the connection portions with the substrate, are arranged in a straight line, interference between the terminals hardly occurs, so that the size of the connector 600 can be suppressed from increasing. Furthermore, since the joint portion with the substrate is on a straight line, the joint portion can be easily inspected.

FIGS. 16A and 16B are perspective views of the connector 500 as seen in FIGS. 14A and 14B. In the connector 500, the structures of terminals 501a, 501b, and 501c forming a group of terminal portions are different from those shown in FIGS. That is, the lower terminal 501c is disposed between the upper terminals 501a and 501b of the group of terminals. The same applies to the other terminal groups. Thereby, even if the end portions 501e to 501g, which are connection portions with the substrate, are arranged in a straight line, the interference between the terminals hardly occurs, so that the size of the connector 500 can be suppressed from increasing. Therefore, in addition to having the same operation and effect as the embodiment of FIGS. 15A and 15B, the terminal can be easily bent.

A connector 700 shown in FIG. 17 has a configuration in which terminals 711a to 711c having end portions 711e to 711g connected to a substrate and terminals (not shown) inside the connector are separated. By processing the terminals 711a to 711c separately from the other parts of the connector 700, it is possible to relatively easily manufacture devices having various accuracy including bending accuracy. Thereby, since the precision of the shape of the edge parts 711e-711f which are a junction part especially with a board | substrate can be made favorable, the connection of a board | substrate and a terminal can be made still better. Various fastening means such as welding, screwing, and riveting can be used for connection between the terminals 711e to 711g and the inside of the connector 500.

DESCRIPTION OF SYMBOLS 1 ... Electric power steering apparatus, 2 ... Steering mechanism, 3 ... Steering wheel, 4 ... Steering shaft, 4a ... Input shaft, 4b ... Output shaft, 4c ... Torsion bar, 5 ... Torque sensor, 5c-5f ... Torque sensor male type Terminals 6 ... Universal joint 7 ... Lower shaft 8 ... Universal joint 9 ... Pinion shaft 10 ... Steering gear 10a ... Pinion 10b ... Rack 11 ... Tie rod 12 ... Steering assist mechanism 13 ... Reduction gear DESCRIPTION OF SYMBOLS 14 ... Brushless motor, 15 ... Control unit, 16 ... Controller, 17 ... Motor drive circuit, 18 ... Vehicle speed sensor, 20 ... Resolver, 21 ... Steering column, 22 ... Reduction gear box, 23 ... Mounting bracket, 24 ... Worm, 25 ... Worm storage part, 26 ... Worm hoist 27, worm wheel storage, 28 ... torque sensor storage, 29 ... motor mounting flange, 30 ... unit mounting surface, 31 ... sensor terminal guide wall, 32 ... unit fixing surface, 40 ... motor case, 41 ... motor flange , 42: Motor power supply terminal block, 43a to 43c ... Motor power supply male terminal, 44 ... Motor power supply guide wall, 50 ... Resolver terminal block, 51a to 51d ... Resolver male terminal, 52 ... Resolver terminal guide wall, 53 ... Case Main body, 54 ... Cover, 55 ... Heat radiation part, 56 ... Torque sensor socket, 56a ... Socket body, 56b to 56e ... Female terminal, 57 ... Motor power supply socket, 58 ... Resolver socket, 59a ... Cylindrical terminal part, 59b ... Elastic deformation part, 59b1, 59b2 ... Opposing rod, 60 ... Unit side mounting part, 61 ... Sensor terminal guide part, 6 ... Opening part, 63 ... Motor power feeding guide part, 64 ... Opening part, 65 ... Resolver terminal guide part, 66 ... Torque sensor socket, 67 ... Motor power feeding socket, 68 ... Resolver socket, 69 ... Unit mounting surface, L ... Steering shaft Axis of M, motor shaft of brushless motor

Claims (7)

A control unit component including a steering shaft to which steering torque is transmitted, an electric motor that transmits a steering assist force to the steering shaft via a speed reduction mechanism in a speed reduction gear box, and a control board that drives and controls the electric motor A plurality of housings connected to the control unit on the reduction gear box and the electric motor, and a unit mounting surface on which the control unit is mounted. The electric motor side connector is formed with the connection direction directed in the same direction, and the control unit is formed with a plurality of control unit side connectors respectively corresponding to the plurality of housings / electric motor side connectors, The plurality of control unit side connectors are connected to the plurality of control units from the connection direction. The electric power steering device is directly connected to the housing / electric motor side connector of the motor. 2. The electric power steering apparatus according to claim 1, wherein the housing / electric motor side connector and the control unit side connector connected to each other are floating type connectors. 3. The electric power steering apparatus according to claim 1, further comprising a guide portion for guiding a connection direction of the control unit side connector and the housing / electric motor side connector. 4. The housing / electric motor side connector is a male terminal, the control unit side connector is a female terminal, and the control unit side connector is the floating type connector. The electric power steering apparatus according to Item 1. 5. The male terminal protection unit for preventing a collision between a tip of the male terminal due to a shift in a connection direction and the control unit side connector at a position different from the female terminal. Electric power steering device. The surface of the control unit mounted on the unit mounting surface is a heat radiating portion, and the reduction gear box and the control unit are fixed from a direction different from the connection direction of the housing / electric motor side connector and the control unit side connector. 6. The electric power steering apparatus according to claim 1, wherein the heat dissipating portion is in surface contact with the unit mounting surface. 7. A torque sensor side connector that connects the plurality of housing / electric motor side connectors to a torque sensor built in the reduction gear box; and a rotation angle sensor side connector that connects to a rotation angle sensor of the electric motor as a brushless motor; A power supply connector for supplying power to the electric motor; a first connector for directly connecting the plurality of control unit side connectors to the torque sensor side connector; and a second connector directly connected to the rotation angle sensor side connector; The electric power steering apparatus according to any one of claims 1 to 6, wherein the electric power steering apparatus is a third connector that is directly connected to the power feeding connector.

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