JP4613798B2 - Connector assembly structure, electrical equipment unit and manufacturing method thereof - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a connector assembly structure, an electrical device unit, and a manufacturing method thereof, and more particularly, to a connector assembly structure for electrically connecting an electrical device in a casing and a device outside the casing, the electrical device unit, and the manufacture thereof. Regarding the method.

2. Description of the Related Art Conventionally, a connector assembly structure for connecting an electric device and an external device is known.
For example, Japanese Patent Laying-Open No. 2005-143200 (Patent Document 1) discloses a connector connected to an inverter unit. Here, the connector is provided with a connector lock portion for reliably maintaining a connection state between the connector on the inverter unit side and the connector on the three-phase power cable side.
JP-A-2005-143200

  Patent Document 1 does not disclose a mechanism for facilitating connector assembly work. In Patent Document 1, the connector lock portion is provided, so that the connector on the inverter unit side and the connector on the power cable side are securely connected. However, in order to facilitate the connector assembly work, Providing a special mechanism is not always an effective measure from the viewpoint of cost saving and space saving.

  The present invention has been made in view of the above problems, and an object of the present invention is a connector capable of facilitating the assembly work of the connector while reducing the size and cost of the casing. It is in providing the assembly structure of this, an electric equipment unit, and its manufacturing method.

An assembly structure of a connector according to the present invention includes an electrical device, a casing having an opening and an insertion port, and housing the electrical device, and is assembled on the outer surface of the casing. And an electrical device is housed in the casing through the opening, the connector is inserted into the insertion slot, and the casing is near the insertion slot with respect to the insertion slot. Provided on the opposite side of the opening, and having a protrusion protruding from the outer surface, and the connector has a terminal inserted into the insertion port and a body holding the terminal, and before the connector is fixed to the casing The terminal inserted through the insertion port is in contact with the casing, and the main body is in contact with the protrusion. In the connector mounting structure, preferably, the protrusion is formed integrally with the casing.

  According to the above configuration, since the temporary storage place for the connector can be formed without providing a special mechanism, the assembly work of the connector can be facilitated while reducing the size and cost of the casing. .

Visible in assembling structure of the connector, by providing the protrusion on the opposite side of the opening portion of the casing relative to the assembly position of the connector, the connector in the state where the temporarily placed on the projections, in the casing from above can do.

In the connector assembly structure described above, preferably, before the connector is fixed to the casing, the terminal inserted through the insertion port contacts the casing and the main body contacts the protruding portion. Than protruding.

  According to the said structure, a connector can be hold | maintained stably because a projection part protrudes rather than the gravity center of a connector in the state which put the connector temporarily.

  In the connector assembly structure, the protrusions are located on both the left and right sides with respect to the center of gravity of the connector when viewed from the direction in which the connector is inserted into the casing. As a result, the connector can be stably held by the protrusions while the connector is temporarily placed.

  Here, “the protrusions are located on both the left and right sides of the center of gravity of the connector” means that a plurality of protrusions are provided so as to sandwich the center of gravity of the connector from both the left and right sides, and one protrusion is the center of gravity of the connector. Extending to both the left and right sides.

  Here, the “left-right direction” means a direction orthogonal to the up-down direction when the connector is assembled as seen from the connector insertion direction.

  In the connector assembly structure, as an example, the electrical device includes an inverter, and the external device includes a rotating electrical machine that drives the vehicle. In this case, it is possible to facilitate the assembly work of the connector while reducing the size and cost of the inverter case.

  In the connector assembling structure, preferably, the protrusion is a part provided as a processing reference when machining the casing.

  When machining the casing, it is necessary to provide a machining standard which is a standard for dimensional management. By providing the protrusion provided as the processing reference in the vicinity of the connector assembly position, the connector assembly operation can be facilitated.

  The electrical equipment unit according to the present invention includes the connector assembly structure described above. Thereby, the assembly | attachment operation | work of a connector can be made easy, aiming at size reduction and cost reduction of an electric equipment unit.

The method of manufacturing an electrical equipment unit according to the present invention includes a step of providing a protrusion on the outer surface of a casing having an insertion opening and an opening, in the vicinity of the insertion opening, on the opposite side of the opening to the insertion opening. A step of housing the electric device in the casing through the opening, and a connector for electrically connecting the device outside the casing and the electric device are placed on the protrusion and the connector is inserted into the insertion port. A step of inserting, a step of fixing the connector placed on the protruding portion to the casing, and a step of electrically connecting the connector to the electrical device after the connector is placed on the protruding portion .

  According to the above method, the connector assembly operation can be facilitated by temporarily placing the connector before being fixed to the casing on the protrusion.

  Preferably, the manufacturing method of the electric equipment unit further includes a step of machining the casing while using the protrusion as a processing reference.

  According to the above method, the protrusion can be used as a temporary storage place for the connector and a processing reference for the casing. Therefore, it can suppress forming a projection part more than necessary.

  Note that “use a protrusion as a processing reference” means that a processing dimension is managed using a specific surface or point in the protrusion as a reference surface or a reference point.

  Preferably, the method for manufacturing the electric device unit further includes a step of positioning the casing while holding the protrusion.

  According to the above method, the protrusion can be used as a temporary storage place for the connector and a positioning means for the casing.

  ADVANTAGE OF THE INVENTION According to this invention, the assembly | attachment operation | work of a connector can be made easy in the assembly | attachment structure of a connector, aiming at size reduction and cost reduction of a casing.

  Embodiments of a connector assembly structure, an electrical equipment unit, and a manufacturing method thereof according to the present invention will be described below. Note that the same or corresponding portions are denoted by the same reference numerals, and the description thereof may not be repeated.

  FIG. 1 is a diagram schematically showing an example of a structure of a drive unit including a connector assembly structure according to one embodiment of the present invention. In the example shown in FIG. 1, the drive unit 1 is a drive unit mounted on a hybrid vehicle, and includes a motor generator 100, a housing 200, a speed reduction mechanism 300, a differential mechanism 400, a drive shaft receiving portion 500, And a terminal block 600.

  The motor generator 100 is a rotating electric machine having a function as an electric motor or a generator. The motor generator 100 is a rotary shaft 110 rotatably attached to the housing 200 via a bearing 120, a rotor 130 attached to the rotary shaft 110, and a stator. 140.

  The rotor 130 includes, for example, a rotor core configured by laminating plate-like magnetic bodies such as iron or an iron alloy, and a permanent magnet embedded in the rotor core. For example, the permanent magnets are arranged at substantially equal intervals in the vicinity of the outer periphery of the rotor core. In addition, you may comprise a rotor core with a powder magnetic core.

  The stator 140 includes a ring-shaped stator core 141, a stator coil 142 wound around the stator core 141, and a bus bar 143 connected to the stator coil 142. The bus bar 143 is connected to a PCU (Power Control Unit) 700 through a terminal block 600 provided in the housing 200 and a power supply cable 700A. PCU 700 is connected to battery 800 via power supply cable 800A. Thereby, battery 800 and stator coil 142 are electrically connected.

  The stator core 141 is configured by, for example, laminating plate-like magnetic bodies such as iron or iron alloy. A plurality of teeth portions (not shown) and slot portions (not shown) as recesses formed between the teeth portions are formed on the inner peripheral surface of the stator core 141. The slot portion is provided so as to open to the inner peripheral side of the stator core 141. In addition, you may comprise the stator core 141 by a dust core.

  Stator coil 142 including three winding phases, U-phase, V-phase, and W-phase, is wound around the tooth portion so as to fit into the slot portion. The U phase, V phase, and W phase of the stator coil 142 are wound so as to deviate from each other on the circumference. Bus bar 143 includes a U phase, a V phase, and a W phase corresponding to the U phase, V phase, and W phase of stator coil 142, respectively.

  The feeding cable 700A is a three-phase cable including a U-phase cable, a V-phase cable, and a W-phase cable. U-phase, V-phase, and W-phase of bus bar 143 are connected to U-phase cable, V-phase cable, and W-phase cable in power supply cable 700A, respectively.

  The power output from the motor generator 100 is transmitted from the speed reduction mechanism 300 to the drive shaft receiving portion 500 via the differential mechanism 400. The driving force transmitted to the drive shaft receiving portion 500 is transmitted as a rotational force to a wheel (not shown) via a drive shaft (not shown), thereby causing the vehicle to travel.

  On the other hand, during regenerative braking of the hybrid vehicle, the wheels are rotated by the inertial force of the vehicle body. Motor generator 100 is driven via drive shaft receiving portion 500, differential mechanism 400 and reduction mechanism 300 by the rotational force from the wheels. At this time, the motor generator 100 operates as a generator. Electric power generated by motor generator 100 is stored in battery 800 via an inverter in PCU 700.

  The drive unit 1 is provided with a resolver (not shown) having a resolver rotor and a resolver stator. The resolver rotor is connected to the rotating shaft 110 of the motor generator 100. The resolver stator has a resolver stator core and a resolver stator coil wound around the core. The rotational angle of the rotor 130 of the motor generator 100 is detected by the resolver. The detected rotation angle is transmitted to the PCU 700. PCU 700 generates a drive signal for driving motor generator 100 using the detected rotation angle of rotor 130 and a torque command value from an external ECU (Electrical Control Unit), and uses the generated drive signal as a motor. Output to the generator 100.

  FIG. 2 is a circuit diagram showing a configuration of a main part of PCU 700. Referring to FIG. 2, PCU 700 includes a converter 710, an inverter 720, a control device 730, capacitors C1 and C2, power supply lines PL1 to PL3, and output lines 740U, 740V, and 740W. Converter 710 is connected between battery 800 and inverter 720, and inverter 720 is connected to motor generator 100 via output lines 740U, 740V, and 740W.

  Battery 800 connected to converter 710 is, for example, a secondary battery such as nickel metal hydride or lithium ion. Battery 800 supplies the generated DC voltage to converter 710 and is charged by the DC voltage received from converter 710.

  Converter 710 includes power transistors Q1 and Q2, diodes D1 and D2, and a reactor L. Power transistors Q1, Q2 are connected in series between power supply lines PL2, PL3, and receive a control signal from control device 730 as a base. Diodes D1 and D2 are connected between the collector and emitter of power transistors Q1 and Q2, respectively, so that current flows from the emitter side to the collector side of power transistors Q1 and Q2. Reactor L has one end connected to power supply line PL1 connected to the positive electrode of battery 800, and the other end connected to a connection point between power transistors Q1 and Q2.

  Converter 710 boosts the DC voltage received from battery 800 using reactor L, and supplies the boosted boosted voltage to power supply line PL2. Converter 710 steps down the DC voltage received from inverter 720 and charges battery 800.

  Inverter 720 includes a U-phase arm 750U, a V-phase arm 750V, and a W-phase arm 750W. Each phase arm is connected in parallel between power supply lines PL2 and PL3. U-phase arm 750U includes power transistors Q3 and Q4 connected in series, V-phase arm 750V includes power transistors Q5 and Q6 connected in series, and W-phase arm 750W includes power transistors connected in series. It consists of transistors Q7 and Q8. Diodes D3 to D8 are respectively connected between the collector and emitter of power transistors Q3 to Q8 so that current flows from the emitter side to the collector side of power transistors Q3 to Q8. The connection point of each power transistor in each phase arm is connected to the anti-neutral point side of each phase coil of motor generator 100 via output lines 740U, 740V, and 740W.

  Inverter 720 converts a DC voltage received from power supply line PL <b> 2 into an AC voltage based on a control signal from control device 730, and outputs the AC voltage to motor generator 100. Inverter 720 rectifies the AC voltage generated by motor generator 100 into a DC voltage and supplies it to power supply line PL2.

  Capacitor C1 is connected between power supply lines PL1 and PL3, and smoothes the voltage level of power supply line PL1. Capacitor C2 is connected between power supply lines PL2 and PL3, and smoothes the voltage level of power supply line PL2.

  Control device 730 calculates each phase coil voltage of motor generator 100 based on the rotation angle of the rotor of motor generator 100, the motor torque command value, each phase current value of motor generator 100, and the input voltage of inverter 720, Based on the calculation result, a PWM (Pulse Width Modulation) signal for turning on / off the power transistors Q3 to Q8 is generated and output to the inverter 720.

  Control device 730 calculates the duty ratio of power transistors Q1 and Q2 for optimizing the input voltage of inverter 720 based on the motor torque command value and the motor rotation speed described above, and power based on the calculation result. A PWM signal for turning on / off the transistors Q 1 and Q 2 is generated and output to the converter 710.

  Further, control device 730 controls switching operations of power transistors Q <b> 1 to Q <b> 8 in converter 710 and inverter 720 in order to charge battery 800 by converting AC power generated by motor generator 100 into DC power.

  In PCU 700, converter 710 boosts a DC voltage received from battery 800 based on a control signal from control device 730, and supplies the boosted voltage to power supply line PL2. Inverter 720 receives the DC voltage smoothed by capacitor C <b> 2 from power supply line PL <b> 2, converts the received DC voltage into an AC voltage, and outputs the AC voltage to motor generator 100.

  Inverter 720 converts the AC voltage generated by the regenerative operation of motor generator 100 into a DC voltage and outputs the DC voltage to power supply line PL2. Converter 710 receives the DC voltage smoothed by capacitor C2 from power supply line PL2, and steps down the received DC voltage to charge battery 800.

  FIG. 3 is a view showing an assembly structure of the connector according to the present embodiment. 4 is a side view of the casing 760 shown in FIG. 3 (viewed from the direction of arrow IV). 5 to 8 are a top view, a top sectional view, a side view, and a side sectional view of the connector 770, respectively. As shown in FIGS. 5 to 8, the connector 770 includes a plurality of terminals 771 and a main body 772 that holds the terminals 771.

  With reference to FIGS. 3 and 4, casing 760 houses inverter 720. A connector 770 is inserted into the side surface of casing 760 from the direction of arrow IV. Three terminals 771 of connector 770 are electrically connected to U-phase arm 750U, V-phase arm 750V, and W-phase arm 750W of inverter 720, respectively.

  The connector 770 is first inserted into the side surface of the casing 760 and is fixed to the casing 760 with a bolt 773. Here, after the connector 770 is inserted into the side surface of the casing 760, it is necessary to support the connector 770 until it is fixed by the bolt 773.

  On the other hand, in the casing 760, a protrusion 761 is provided in the vicinity of the insertion port of the connector 770. The casing 770 is a die-cast case made of, for example, aluminum, and the protrusion 761 is formed integrally with the casing 760 when the casing 760 is formed. Further, the protrusion 761 includes a plurality (two) of protrusions 761A and 761B formed so as to be aligned in the extending direction of the insertion port of the connector 770. The protrusions 761A and 761B can support the main body 772 of the connector 770 before being fixed to the casing 760 by the bolt 773. Therefore, after the connector 770 is inserted into the side surface of the casing 760, the connector 770 can be temporarily placed on the protrusions 761A and 761B when the bolt 773 is prepared. It is possible. As a result, the assembly work of the connector 770 becomes easy.

  3 and 4, the working casing 760 is open upward. On the other hand, the protrusions 761A and 761B are located below the insertion port of the connector 770. That is, the protrusions 761A and 761B are provided on the opposite side of the opening of the casing 760 with respect to the assembly position of the connector 770. By doing so, the inside of the casing 760 can be viewed from the upper side with the connector 770 temporarily placed on the protrusions 761A and 761B, so that the subsequent work (for example, coupling between terminals in the casing 760) ) Is easier to perform.

  FIG. 9 is a diagram illustrating a state where the connector 770 temporarily placed on the protrusion 761 is viewed from the side of the connector. Referring to FIG. 9, in connector 770 temporarily placed on protrusion 761, terminal 771 is in contact with casing 760 in a state of being inserted into insertion port 762 provided in casing 760. It is in contact with the part 761. In this state, the connector 770 protrudes from the protrusion 761. On the other hand, the protrusion 761 protrudes from the center of gravity G of the connector 770. By doing so, the connector 770 can be stably held by the protrusion 761. 9 illustrates an example in which the connector 770 temporarily placed on the protrusion 761 protrudes from the protrusion 761, but the connector 770 does not necessarily protrude from the protrusion 761. In the state where 770 is temporarily placed on the protrusion 761 and the protrusion 761 protrudes from the connector 770, the protrusion 761 serves as a temporary place for the connector 770 as described above.

  10 and 11 are views showing a state where the connector 770 temporarily placed on the protrusion 761 is viewed from the insertion direction of the connector 770 (the direction of the arrow IV in FIG. 3). As shown in FIG. 10, the two protrusions 761 </ b> A and 761 </ b> B are located on the left and right sides with respect to the center of gravity G of the connector 770 when viewed from the insertion direction of the connector 770. By doing so, the connector 770 can be stably held by the protrusion 761. Note that the number of the protrusions 761 is not necessarily plural, and the connector 770 can be stably held by one protrusion 761 as shown in FIG. In this case, the protrusion 761 is provided so as to extend on both the left and right sides of the center of gravity of the connector 770.

  The casing 760 is machined. At this time, for example, the upper surface of the protrusion 761 can be used as a reference surface for dimensional management. That is, the protrusion 761 may be used as a processing reference when the casing 760 is machined.

  The above contents are summarized as follows. That is, the connector connection structure according to the present embodiment includes an inverter 720 as an “electrical device”, a casing 760 that houses the inverter 720, and an “device” outside the casing 760 that is assembled on the outer surface of the casing 760. And the connector 770 for electrically connecting the motor generator 100 and the inverter 720, and the casing 760 includes protrusions 761A and 761B provided in the vicinity of the assembly position of the connector 770.

  Further, in the method of manufacturing the PCU 700 as the “electric equipment unit” according to the present embodiment, as shown in FIG. 12, a step (S10) of providing a protrusion 761 (761A, 761B) on the outer surface of the casing 760, A step of housing the inverter 720 in the casing 760 (S20), and a connector 770 for electrically connecting the motor generator 100, which is an “apparatus” outside the casing 760, and the inverter 720 are provided on the protrusions 761A and 761B. A placing step (S30), and a step (S40) for fixing the connector 770 placed on the protrusions 761A and 761B to the casing 760.

  According to the assembly structure of the connector according to the present embodiment, a temporary storage place for the connector 770 can be formed without providing a special mechanism, so that the connector 760 can be reduced in size and cost while the connector 770 is reduced. Assembling work 770 can be facilitated.

  In the manufacturing process of the PCU 700, the protrusions 761A and 761B may be used for other purposes. For example, it is conceivable to position the casing 760 while holding the protrusions 761A and 761B with a chuck. In this case, the protrusions 761A and 761B can be used as a temporary storage place for the connector 770 and a positioning means for the casing 760.

  Although the embodiments of the present invention have been described above, the embodiments disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is a figure which shows roughly an example of the structure of the drive unit containing the assembly | attachment structure of the connector which concerns on one embodiment of this invention. It is a circuit diagram which shows the structure of the principal part of PCU shown by FIG. It is the figure which showed the assembly | attachment structure of the connector which concerns on one embodiment of this invention. FIG. 4 is a side view of the casing shown in FIG. 3. FIG. 4 is a top view of the connector shown in FIG. 3. FIG. 4 is a top cross-sectional view of the connector shown in FIG. 3. FIG. 4 is a side view of the connector shown in FIG. 3. It is side surface sectional drawing of the connector shown by FIG. It is a figure which shows the state which looked at the connector temporarily set | placed on the projection part from the side surface of this connector. It is FIG. (1) which shows the state which looked at the connector temporarily set | placed on the projection part from the insertion direction of this connector. FIG. 11 is a diagram (No. 2) illustrating a state in which the connector temporarily placed on the protrusion is viewed from the insertion direction of the connector. It is a flowchart explaining the manufacturing method of the electric equipment unit which concerns on one embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Drive unit, 100 Motor generator, 110 Rotating shaft, 120 Bearing, 130 Rotor, 140 Stator, 141 Stator core, 142 Stator coil, 143 Bus bar, 200 Housing, 300 Reduction mechanism, 400 Differential mechanism, 500 Drive shaft receiving part, 600 Terminal Stand, 700 PCU, 700A, 800A feeding cable, 710 converter, 720 inverter, 730 control device, 740U, 740V, 740W output line, 750U U-phase arm, 750V V-phase arm, 750W W-phase arm, 760 casing, 761, 761A 761B Protrusion, 762 insertion port, 770 connector, 771 terminal, 772 body, 773 bolt, 800 battery, C1, C2 Sensor, D1-D8 diode, L reactor, PL1, PL2, PL3 power line, Q1-Q8 power transistor.

Claims (10)

Electrical equipment ,
A casing having an opening and an insertion opening and housing the electrical device;
A connector that is assembled on the outer surface of the casing, and that electrically connects an external device of the casing and the electrical device ;
The electrical device is housed in the casing through the opening,
The connector is inserted into the insertion slot,
The casing is provided in the vicinity of the insertion opening, provided on the opposite side of the opening with respect to the insertion opening, and having a protrusion protruding from the outer surface,
The connector has a terminal inserted through the insertion port and a body holding the terminal,
Before the connector is fixed to the casing, the connector assembly structure in which the terminal inserted through the insertion port is in contact with the casing and the main body is in contact with the protrusion . The connector assembling structure according to claim 1, wherein the protrusion is formed integrally with the casing. Before the connector is fixed to the casing, the terminal inserted into the insertion port is in contact with the casing, and the main body is in contact with the protrusion. The assembly structure of the connector according to claim 1 or 2, which protrudes.   4. The connector assembly structure according to claim 1, wherein the protrusions are located on both the left and right sides with respect to the center of gravity of the connector as viewed from the insertion direction of the connector into the casing. 5. The electrical device includes an inverter,
5. The connector assembly structure according to claim 1, wherein the external device includes a rotating electrical machine that drives a vehicle.   The connector assembling structure according to any one of claims 1 to 5, wherein the protrusion is a portion provided as a processing reference when machining the casing.   An electrical equipment unit comprising the connector assembly structure according to any one of claims 1 to 6. A step of providing a protrusion on the outer surface of the casing having the insertion opening and the opening, in the vicinity of the insertion opening, on the opposite side of the opening with respect to the insertion opening ;
Storing an electrical device in the casing through the opening ;
Placing a connector for electrically connecting the device outside the casing and the electrical device on the protrusion and inserting the connector into the insertion port ;
Fixing the connector placed on the protrusion to the casing ;
And a step of electrically connecting the connector to the electric device after placing the connector on the protrusion .   The manufacturing method of the electric equipment unit according to claim 8, further comprising a step of machining the casing while using the protrusion as a processing reference.   The method for manufacturing an electrical equipment unit according to claim 8, further comprising a step of positioning the casing while holding the protrusion.

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