JP5208578B2 - Motor unit and method for manufacturing motor unit - Google Patents

Description

  The present invention relates to a motor unit and a method for manufacturing the motor unit.

  2. Description of the Related Art Conventionally, a vehicle equipped with a vehicle power train that is driven by a motor, such as a fuel cell vehicle or an electric vehicle, is known. In addition, a PDU (power drive unit) having an inverter for supplying electric power to drive a motor or charging regenerative electric power from the motor is supplied to a vehicle having such a vehicle power train. And a battery is provided.

  This vehicle powertrain is generally disposed in a motor room (equivalent to an engine room of an engine car) in front of the vehicle body. On the other hand, the PDU connected to the vehicle power train is disposed below the floor panel at the center of the vehicle body (see, for example, Patent Document 1). When the installation position of the vehicle power train and the PDU is thus separated, the distance of the three-phase cable provided between them becomes longer, making the layout difficult, and the heat loss from the copper wire constituting the three-phase cable. There is a problem that it occurs or the weight of the vehicle increases.

In order to solve these problems, Patent Document 1 proposes a vehicle powertrain casing and a PDU casing that are integrally attached. By configuring in this way, the three-phase cable can be shortened, and it can contribute to the suppression of heat generation and weight reduction due to electrical resistance.
JP-A-11-180163

  By the way, in the structure of Patent Document 1 described above, the casing of the vehicle powertrain and the casing of the PDU are integrally fastened, and the connectors are connected so that the length of the three-phase cable is the shortest between them. The connection structure at both ends of the phase cable has not been studied for a structure for absorbing vibration, and there is a risk of disconnection of the motor winding or poor conduction of the PDU parts. This is because even if the casing of the vehicle powertrain and the casing of the PDU are integrally fastened, if they vibrate, they do not vibrate completely in the same phase, so three-phase power lines (motor winding, PDU bus bar, etc.) This is because stress is applied to the three-phase power line if it is not fixed to each casing. In addition, in the method of connecting between the two using a bus bar instead of the cable, there is a risk that contact between the bus bar and the terminal block may be poor due to insufficient vibration absorption when the casing vibrates. .

  Accordingly, the present invention has been made in view of the above circumstances, and provides a motor unit and a method of manufacturing the motor unit that are not easily affected by vibration and that can suppress heat generation and reduce weight due to electrical resistance. It is to provide.

In order to solve the above-described problem, the invention described in claim 1 includes a motor case (for example, the motor case 15 in the embodiment) in which a motor (for example, the motor 23 in the embodiment) is accommodated, and a PDU (for example, in the embodiment). The PDU case (for example, the PDU housing 62 in the embodiment) in which the PDU 61 in the embodiment is accommodated is fastened so as to be integrated, and is disposed in the motor case, and the motor terminal (for example, the motor winding in the embodiment) A motor terminal block (for example, the motor terminal block 70 in the embodiment) to which the wire 73) is connected, and a PDU terminal block that is disposed in the PDU case and connected to the PDU terminal (for example, the PDU bus bar 63 in the embodiment). (For example, the PDU terminal block 65 in the embodiment), the motor terminal block and the PDU terminal block A three-phase cable (for example, the three-phase cable 71 in the embodiment) that connects between the motor case and the PDU case in order to insert the three-phase cable (for example, an opening in the embodiment) 84,68) a motor unit which is formed, between the contact surface of the edge forming the opening edge and the PDU case of forming the opening of the motor casing is sealed, the motor The opening of the case and the opening of the PDU case allow the three-phase cable to pass through with a gap, and the three-phase cable forms an edge that forms the opening of the motor case and the opening of the PDU case. It is characterized by being spaced apart from the edge .
In the invention described in claim 2, the PDU case is placed on the upper side of the motor case, and a connection point between the PDU terminal block and a connection point with the motor terminal block in the three-phase cable is It is characterized by being displaced in the horizontal direction.

In the invention described in claim 3 , LA terminals (for example, the LA terminals 54 and 56 in the embodiment) are provided at both ends of the three-phase cable, and the LA terminal, the motor terminal block, and the PDU terminal block are connected to each other. It is characterized by being connected.

According to a fourth aspect of the present invention, the motor case in which the motor is accommodated and the PDU case in which the PDU is accommodated are fastened so as to be integrated, arranged in the motor case, and connected to the motor terminal. A motor terminal block, a PDU terminal block disposed in the PDU case and connected to a PDU terminal, and a three-phase cable connecting the motor terminal block and the PDU terminal block; An opening is formed in the motor case and the PDU case for inserting a cable, and a gap between an abutting surface forming an opening of the motor case and an edge forming an opening of the PDU case is between Sealed, the opening of the motor case and the opening of the PDU case allow the three-phase cable to be inserted with a gap, and the three-phase cable is an opening of the motor case. A method of manufacturing a motor unit arranged spaced apart from the edge forming the opening edge and the PDU case formed, a step of connecting one end of said 3-phase cable to the PDU terminal block, the A step of inserting the other end of the three-phase cable through the opening and placing the other end on the motor case side, and inserting a tool from an attachment opening formed in the motor case (for example, the opening 82 in the embodiment) And connecting the other end of the three-phase cable to the motor terminal block and closing the mounting opening with a lid member.

According to the first and second aspects of the present invention, since the motor case and the PDU case are integrally fastened, the influence of the vibration that the three-phase cable receives can be minimized. In addition, since the length of the three-phase cable laid between the motor terminal block accommodated in the motor case and the PDU terminal block accommodated in the PDU case can be shortened, heat generation is suppressed and weight is reduced due to electrical resistance. Can be reduced. In addition, since the motor case and the PDU case can be metal touched by connecting the opening of the motor case and the opening of the PDU case via a seal material (O-ring), the shield wire for grounding Can be abolished. Furthermore, waterproofness is securable by connecting the opening part of a motor case and the opening part of a PDU case via a sealing material (O-ring).

According to the invention described in claim 3 , by using the LA terminal at the connection point between the terminal block and the three-phase cable, it is possible to save the space at the connection point. That is, it is possible to reduce the size of the motor case and the PDU case. Further, by using the LA terminal, the terminal can be easily attached and detached, and the assemblability of the case integration is improved. Therefore, even if the motor unit vibrates, the vibration between cases can be absorbed by the three-phase cable, so that the motor windings and PDU conduction parts (busbars) are less susceptible to vibration, and can be easily It becomes possible to suppress heat generation by resistance and reduce weight.

According to the invention described in claim 4 , since the motor case and the PDU case are integrally fastened, the three-phase laid between the motor terminal block accommodated in the motor case and the PDU terminal block accommodated in the PDU case. The length of the cable can be shortened. Therefore, heat generation due to electrical resistance can be suppressed and weight can be reduced. In addition, after the PDU terminal block and the three-phase cable are fastened and fixed, the motor terminal block and the three-phase cable are fastened and fixed, so that the three-phase cable is securely fastened to the terminal block with the minimum fastening opening. And a highly reliable motor unit can be manufactured.

Next, an embodiment of the present invention will be described with reference to FIGS.
FIG. 1 is a schematic sectional view of a motor unit. As shown in FIG. 1, the motor unit 100 includes a vehicle power train (hereinafter referred to as a power train) 10 that houses a motor 23, and a PDU 61 that houses an inverter 75. The motor unit 100 has a configuration in which a PDU 61 is placed above the power train 10.

  The power train 10 includes a motor housing 11 that houses a motor 23 having a stator portion 21 and a rotor portion 22, and a power transmission portion that is fastened to one side of the motor housing 11 and that transmits power from the output shaft 24 of the motor 23. A transmission housing 12 that houses (not shown) and a sensor housing 13 that is fastened to the other side of the motor housing 11 and houses the rotation sensor 25 of the motor 23. That is, the motor housing 11, the mission housing 12 and the sensor housing 13 constitute a motor case 15. The mission housing 12 includes a common housing 12A fastened to the motor housing 11 and a gear housing 12B fastened to the common housing 12A. The motor housing 11 is configured as a motor chamber 36, the mission housing 12 is configured as a mission chamber 37, and the sensor housing 13 is configured as a sensor chamber 38.

  The motor housing 11 is formed in a substantially cylindrical shape so as to cover the entire motor 23. A bearing 26 that rotatably supports one end of the output shaft 24 of the motor 23 is provided on the mission housing 12 side of the boundary between the motor housing 11 and the mission housing 12, and the boundary between the motor housing 11 and the sensor housing 13. On the sensor housing 13 side, a bearing 27 that rotatably supports the other end of the output shaft 24 of the motor 23 is provided.

  Further, a breather passage 35 communicating with each other is formed in the wall portion 31 of the motor housing 11, the wall portion 32 of the transmission housing 12, and the wall portion 33 of the sensor housing 13.

  Here, in the wall portion 31 of the motor housing 11, a water jacket 55 for cooling the motor 23 is provided on the inner peripheral side of the breather passage 35 so as to cover the entire circumference of the stator portion 21 of the motor 23. Yes. The stator portion 21 is shrink-fitted into the motor housing 11 and is disposed so as to be in close contact with the inner peripheral surface of the motor housing 11.

  A breather chamber 51 for separating the lubricating oil used in the powertrain 10 is formed in the mission housing 12. That is, the lubricating oil scattered by the rotation of the power transmission unit (gear) and the motor 23 can be separated in the breather chamber 51, and the lubricating oil leaks to the outside from the breather pipe 39 provided in the breather chamber 51 and communicating with the outside. This can be prevented.

  The breather chamber 51 is formed at a position corresponding to the uppermost portion of the power train 10. The breather chamber 51 communicates with the breather passage 35 so that high-pressure and high-temperature air in the power train 10 can be discharged from the breather pipe 39. Further, the breather chamber 51 communicates with the motor chamber 36, the mission chamber 37, and the sensor chamber 38 via the breather passage 35.

  Here, the power train 10 is provided with a motor terminal block 70 for electrically connecting the three-phase cable 71 connected to the PDU 61 and the motor winding 73 of the motor 23. The motor terminal block 70 is attached to a wall 77 (described later in detail) of the sensor housing 13 facing the motor chamber 36. A three-phase cable 71 is laid between the motor terminal block 70 and the PDU terminal block 65 provided on the PDU 61, and the motor 23 and the inverter 75 are electrically connected. The sensor housing 13 is provided with a three-phase cable 71 and a connection chamber 81 for connecting the three-phase cable 71 and the motor terminal block 70.

  Next, the PDU 61 is placed above the power train 10. The PDU 61 includes a PDU housing 62 having a substantially box shape, and an inverter 75, a capacitor 76, and the like are accommodated in the PDU housing 62. The inverter 75 is provided with a PDU bus bar 63. The PDU bus bar 63 extends toward the PDU terminal block 65 that is also housed in the PDU housing 62, and the PDU bus bar 63 and the PDU terminal block 65 are fastened and fixed by fastening bolts 64 (see FIG. 2). Yes. The PDU bus bar 63 connected to the PDU terminal block 65 and the three-phase cable 71 are electrically connected by fastening bolts 80.

FIG. 2 is a detailed view of part A of FIG. FIG. 2 shows a cross section in which the breather passage 35 is not formed. In addition, for convenience of explanation, a partly oblique perspective view is shown.
As shown in FIG. 2, the stator portion 21 and the rotor portion 22 constituting the motor 23 are arranged in the motor housing 11. The stator portion 21 includes a stator core 21A in which a plurality of substantially annular plate members are stacked, and a motor winding span portion 21B wound around the stator core 21A. Three motor windings 73 are extended from the motor winding span 21 </ b> B toward the motor terminal block 70. Then, an LA terminal motor terminal 53 is provided at the end of the motor winding 73 and is fastened to the motor terminal block 70 via a fastening bolt 74. In order to fasten the fastening bolt 74 to the motor terminal block 70, an opening 41 is formed in the top surface 13 </ b> A of the sensor housing 13, and a lid member 42 is provided to close the opening 41.

A wall 77 is erected between the top surface 13A and the bottom surface 13B of the sensor housing 13 at a position where the motor terminal block 70 is attached. An opening 78 is formed in the wall 77, and the three-phase cable connection portion 43 of the motor terminal block 70 is inserted into the opening 78. Specifically, an opening 78 through which a three-phase cable connection portion 43 corresponding to each phase of the motor 23 can be inserted is formed in the wall portion 77. That is, when the motor terminal block 70 is attached from the motor housing 11 side of the wall portion 77, the three-phase cable connection portion 43 of the motor terminal block 70 protrudes to the connection chamber 81 side of the wall portion 77 and is provided on the motor terminal block 70. The heat radiating plate 50 and the wall 77 are in contact with each other.
In this state, a screw is inserted through a screw hole (not shown) formed in the heat radiating plate 50, and the heat radiating plate 50 and the wall portion 77 are metal-touched (contacted) to be fastened and fixed. In addition, between the heat sink 50 and the wall part 77, it seals and clamp | tightens and fixes in the state which applied the liquid packing.

  Next, in the connection chamber 81, the three-phase cable connection portion 43 of the motor terminal block 70 and the three-phase cable 71 are connected. Specifically, the LA terminal 54 is provided at the end of the three-phase cable 71 and is fastened to the motor terminal block 70 via fastening bolts 79. In order to fasten the fastening bolt 79 to the motor terminal block 70, an opening 82 is formed in the side surface 13 </ b> C of the sensor housing 13, and a lid member 83 is provided to close the opening 82.

  The three three-phase cables 71 are inserted into the PDU 61 through the opening 84 formed in the upper portion of the connection chamber 81 and through the opening 68 formed in the lower surface of the PDU housing 62. ing. The PDU housing 62 is provided with a three-phase cable 71 and a connection chamber 85 for fastening the three-phase cable 71 to the PDU terminal block 65.

  In the PDU terminal block 65 of the connection chamber 85, the PDU bus bar 63 and the three-phase cable 71 are connected. Specifically, the LA terminal 56 is provided at the end of the three-phase cable 71, and the PDU bus bar 63 and the three-phase cable 71 are connected via the fastening bolt 80.

  In addition, the connection location with the motor terminal block 70 in the three-phase cable 71 and the connection location with the PDU terminal block 65 (PDU bus bar 63) are shifted in the horizontal direction in the front view of the motor unit 100, and the PDU terminal block The connection location with 65 is located on the outer side in the vehicle width direction. That is, the three-phase cable 71 is laid so as to be inclined in a front view. With this configuration, the length of the three-phase cable can be given a slight margin, and can be followed when the motor unit 100 vibrates.

(Manufacturing method of motor unit)
Next, a manufacturing method (assembly method) of the motor unit 100 will be described. Here, the method for connecting the three-phase cable 71 will be mainly described.
First, the three-phase cable 71 is connected to the PDU terminal block 65 of the PDU 61. Specifically, the LA terminal 56 attached to one end of the three-phase cable 71 is aligned with the connection portion with the PDU bus bar 63, and the fastening bolt 80 is fastened and fixed thereto. The other end of the three-phase cable 71 is arranged so as to protrude from the opening 68 of the PDU housing 62.
The other end of the three-phase cable 71 is inserted into the opening 84 of the motor case 15 (sensor housing 13), the opening 68 of the PDU housing 62 and the opening 84 of the motor case 15 are brought into contact with each other, and fixed with bolts or the like. To do. At this time, the sealing member (O-ring) is abutted between the opening 68 of the PDU housing 62 and the opening 84 of the motor case 15 and is fastened and fixed.

  Next, the three-phase cable 71 is connected to the motor terminal block 70 of the power train 10. Specifically, the LA terminal 54 attached to the other end of the three-phase cable 71 is aligned with the three-phase cable connecting portion 43 of the motor terminal block 70, and a fastening bolt 79 is fastened and fixed thereto. When the fastening bolt 79 is fastened and fixed, a tool (not shown) is inserted from the opening 82 formed in the side surface 13C of the sensor housing 13 and the fastening bolt 79 is fastened. When the tightening of the fastening bolt 79 is completed, the opening 82 is closed by the lid member 83, and the connection of the three-phase cable 71 is completed.

(Function)
The operation of the motor unit 100 configured as described above will be described.
During driving of the vehicle, vibrations transmitted from the tires, vibrations generated by driving the motor 23, and the like are generated, and the vibrations are also transmitted to the motor unit 100. When the motor unit 100 vibrates, the motor case 15 and the PDU housing 62 including the motor housing 11, the mission housing 12, and the sensor housing 13 also vibrate. Since the motor case 15 and the PDU housing 62 are fastened and fixed by bolts or the like, they basically vibrate in the same phase, but vibration stress applied to the three-phase cable 71 is generated. However, in this embodiment, the LA terminals 54 and 56 are attached to both ends of the three-phase cable 71, and the LA terminals 54 and 56 are respectively connected to the motor terminal block 70 and the PDU terminal block 65 (PDU bus bar 63) with fastening bolts 79 and 80. Since it is fastened and fixed, the vibration can be absorbed and followed only by the three-phase cable 71 without transmitting the vibration to the motor winding 73 and the PDU bus bar 63. Further, by giving a slight margin to the size of the bolt insertion holes of the LA terminals 54 and 56, it is possible to improve the workability with respect to assembly variations. Still further, the three-phase cable 71 can be made to follow the vibration by being inclined so as to have a slight margin in front view. Therefore, it is possible to absorb vibrations reliably and cheaper than the conventional connector connection and bus bar connection.

  According to the present embodiment, since the motor case 15 (the motor housing 11, the transmission housing 12, and the sensor housing 13) and the PDU housing 62 are integrally fastened, the motor terminal block 70 and the PDU housing 62 accommodated in the motor case 15 are connected to each other. The length of the three-phase cable 71 laid between the accommodated PDU terminal block 65 can be shortened. Therefore, heat generation due to electrical resistance can be suppressed and weight can be reduced. Further, since the opening 84 of the motor case 15 and the opening 68 of the PDU housing 62 are connected via a sealing material (O-ring), the motor case 15 and the PDU housing 62 can be metal touched. It becomes possible to cancel the shield wire for grounding. Furthermore, by connecting the opening 84 of the motor case 15 and the opening 68 of the PDU housing 62 via a sealing material (O-ring), waterproofness can be ensured while following vibration.

  Further, by using the LA terminals 54 and 56 at the connection points between the terminal blocks 65 and 70 and the three-phase cable 71, it is possible to save space at the connection points. That is, the motor case 15 and the PDU housing 62 can be reduced in size. Further, by using the LA terminals 54 and 56, the terminals can be easily attached and detached, and the assemblability of the case integration is improved. Therefore, even if the motor unit 100 vibrates, the vibration between the cases can be absorbed by the three-phase cable 71, so that the motor winding 73 and the PDU conduction component (PDU bus bar 63) are not easily affected by the vibration and are simple. By mounting, it is possible to suppress heat generation due to electrical resistance and reduce weight.

  Furthermore, after the PDU terminal block 65 and the three-phase cable 71 are fastened and fixed, the motor terminal block 70 and the three-phase cable 71 are fastened and fixed, so that the three-phase cable 71 is securely fastened to the terminal blocks 65 and 70. Therefore, the highly reliable motor unit 100 can be manufactured.

The present invention is not limited to the above-described embodiment, and includes various modifications made to the above-described embodiment without departing from the spirit of the present invention. In other words, the specific structures and materials described in the embodiments are merely examples, and can be changed as appropriate.
For example, in this embodiment, the three-phase cable is inclined so that the connection location with the PDU terminal block is located on the outer side in the vehicle width direction than the connection location with the motor terminal block. You may incline and arrange so that the connection location with a motor terminal block may be located in the vehicle width direction outer side rather than the connection location with a terminal block. Further, the three-phase cable need not be inclinedly arranged in front view.

It is a schematic structure sectional view of a power train in an embodiment of the present invention. FIG. 2 is a detailed view of part A in FIG. 1.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 15 ... Motor case 23 ... Motor 54, 56 ... LA terminal 61 ... PDU 62 ... PDU housing (PDU case) 63 ... PDU bus bar (PDU terminal) 65 ... PDU terminal block 68 ... Opening 70 ... Motor terminal block 71 ... Three-phase Cable 73 ... Motor winding 77 ... Wall 82 ... Opening (mounting opening) 83 ... Lid member 84 ... Opening 100 ... Motor unit

Claims (4)

The motor case in which the motor is accommodated and the PDU case in which the PDU is accommodated are fastened so as to be integrated,
A motor terminal block disposed in the motor case and connected to a motor terminal;
A PDU terminal block disposed in the PDU case and connected to a PDU terminal;
A three-phase cable connecting between the motor terminal block and the PDU terminal block;
A motor unit in which an opening is formed in the motor case and the PDU case for inserting the three-phase cable,
During the contact surface of the edge forming the opening edge and the PDU case of forming the opening of the motor casing is sealed,
The opening of the motor case and the opening of the PDU case are inserted through the three-phase cable with a gap,
The motor unit, wherein the three-phase cable is disposed apart from an edge forming an opening of the motor case and an edge forming an opening of the PDU case . The PDU case is placed on the upper side of the motor case,
2. The motor unit according to claim 1, wherein a connection location of the three-phase cable with the PDU terminal block and a connection location of the motor terminal block are shifted in the horizontal direction. The motor unit according to claim 1 or 2 , wherein LA terminals are provided at both ends of the three-phase cable, and the LA terminal is connected to the motor terminal block and the PDU terminal block. The motor case in which the motor is accommodated and the PDU case in which the PDU is accommodated are fastened so as to be integrated,
A motor terminal block disposed in the motor case and connected to a motor terminal;
A PDU terminal block disposed in the PDU case and connected to a PDU terminal;
A three-phase cable connecting between the motor terminal block and the PDU terminal block;
An opening is formed in the motor case and the PDU case for inserting the three-phase cable ,
The space between the contact surface between the edge forming the opening of the motor case and the edge forming the opening of the PDU case is sealed,
The opening of the motor case and the opening of the PDU case are inserted through the three-phase cable with a gap,
The three-phase cable is a method of manufacturing a motor unit that is arranged apart from an edge part that forms an opening part of the motor case and an edge part that forms an opening part of the PDU case ,
Connecting one end of the three-phase cable to the PDU terminal block;
Placing the other end of the three-phase cable on the motor case side through the opening;
Inserting a tool from the mounting opening formed in the motor case and connecting the other end of the three-phase cable to the motor terminal block;
And a step of closing the mounting opening with a lid member.

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