JP6695769B2 - Electric drive - Google Patents

Description

  The present invention relates to an electric drive device, and more particularly, to an electric drive device having an electronic control device built therein.

  In a general industrial machine field, a mechanical system control element is driven by an electric motor, but recently, an electronic control device including a semiconductor element for controlling the rotation speed and the rotation torque of the electric motor is electrically driven. A so-called electromechanical integrated electric drive device, which is integrally incorporated into a motor, has begun to be adopted.

  As an example of the electromechanical integrated electric drive device, for example, in an electric power steering device for an automobile, a driver detects a turning direction and a turning torque of a steering shaft that is turned by operating a steering wheel, The electric motor is driven so as to rotate in the same direction as the rotation direction of the steering shaft based on the detected value, and the steering assist torque is generated. An electronic control unit (ECU: Electronic Control Unit) is provided in the power steering device to control the electric motor.

  As a conventional electric power steering device, for example, one disclosed in Japanese Patent Application Laid-Open No. 2015-134598 (Patent Document 1) is known. Patent Document 1 describes an electric power steering device including an electric motor and an electronic control device. The electric motor is housed in a motor housing having a tubular portion made of aluminum alloy or the like, and the electronic control unit is housed in an ECU housing arranged on the opposite side of the motor housing from the output shaft in the axial direction. There is. An electronic control unit housed inside an ECU housing includes a power supply circuit section, a power conversion circuit section having a power switching element such as MOSFET for driving and controlling an electric motor, and a control circuit section for controlling the power switching element. The output terminal of the power switching element and the input terminal of the electric motor are electrically connected via a bus bar.

  The electronic control unit housed in the ECU housing is supplied with electric power from a power supply via a connector terminal assembly made of synthetic resin, and is supplied with detection signals such as operating states from detection sensors. .. The connector terminal assembly functions as a lid, is connected to the electronic control unit so as to close an opening formed in the ECU housing, and is fixed to the outer surface of the ECU housing by a fixing bolt.

  In addition to the above, as an electric drive unit in which an electronic control unit is integrated, an electric brake, an electric hydraulic controller for various hydraulic controls, and the like are known.

JP, 2005-134598, A

  Since the electric power steering device described in Patent Document 1 is arranged in the engine room of the automobile, it is necessary to have a small size. In particular, recently, in the engine room of automobiles, there is a tendency that many accessories such as exhaust gas countermeasure equipment and safety countermeasure equipment are installed, and various accessories such as the electric power steering device should be miniaturized as much as possible. It has been demanded.

  For example, the electric power steering device has a relatively small axial length limitation in the longitudinal direction because of its structure, and tends to be limited in radial size. Therefore, under the present circumstances, it is required to reduce the size of the housing in the radial direction.

  In order to reduce the size in the radial direction, it is effective to separately divide the power supply circuit unit, the power conversion circuit unit, and the control circuit unit into three. According to this, since the electric components necessary for controlling the electric motor are divided into three, the size can be reduced in the radial direction.

  By the way, in the electric drive device to which the present invention is applied, as shown in FIGS. 15 and 16, the connection portion for supplying power from the power supply circuit unit to the power conversion circuit unit is provided in the power supply circuit unit. Of the substantially “L” -shaped inverter side connector terminal 63 in which the flat plate portion (= inverter side wiring terminal) 60F of the power source side wiring terminal 60 extending from the high voltage side connector terminal is provided on the substrate 62 of the power conversion circuit unit 61. The flat plate portion 63F is superposed on the flat portion 63F, and the tip of the superposed portion is TIG-welded and connected by the welded portion W.

  Since the flat plate portion of the power supply side wiring terminal 60 and the flat plate portion 63F of the inverter side connector terminal 63 are superposed and joined to each other, the inverter side connector terminal 63 may be arranged close to the power supply side wiring terminal 60. Will be needed. Since the flat plate portion 63F of the "L" -shaped inverter-side connector terminal 63 is connected to the flat plate portion 60F of the power-source-side wiring terminal 60, the flat plate portion 63F of the inverter-side connector terminal 63 is a substrate of the power conversion circuit unit. It is configured to extend beyond the end surface 62E of 62 to the power supply side wiring terminal 60 by a length g.

  By the way, the substrate 62 of the power conversion circuit unit 61 is covered with a resist film which is an insulating film except for the wiring pattern, and the inverter-side connector terminals 63 soldered to the wiring pattern are also provided on the upper surface of the resist film from the wiring pattern. In a contact state, it extends beyond the end face 62E of the substrate 62 to the power supply side wiring terminal 60 by a length g. For this reason, there arises a problem that a high-voltage current flowing through the inverter-side connector terminal 63 that is in contact with the upper surface of the resist film increases the risk of dielectric breakdown in the resist film.

  The inverter-side connector terminal 63 is placed on the board 62 and is bonded and fixed to the wiring pattern of the board 62 by soldering. Soldering of the inverter-side connector terminal 63 is generally performed by a "reflow process". In the "reflow process", paste-like solder called cream solder is applied according to the wiring pattern in advance, and the inverter-side connector terminal 63 is placed thereon to directly heat the substrate 62 to melt the solder. This is a method of soldering with.

  As described above, in the electric drive device targeted by the present invention, it is required to reduce the area of the substrate 62 so as to be miniaturized in the radial direction, and the mounting area of the inverter-side connector terminal 63 is also required. It is necessary to reduce it as much as possible. Therefore, the adhesion surface of the inverter-side connector terminal 63 also tends to be narrowed.

  When the "L" -shaped inverter-side connector terminal 63 is used, the mounting stability of the inverter-side connector terminal 63 in the mounted state is poor. For this reason, it is difficult to make the solder stand alone by the adhesive force of the paste-like solder alone. Further, when the solder melts in the soldering process, the "L" -shaped co-inverter-side connector terminal 63 may fall. Therefore, it is necessary to make the inverter-side connector terminal 63 self-supporting by using special employment, and there is a problem that productivity cannot be improved.

  In the above description, the inverter-side connector terminal is taken as an example, but the same applies to a general connector terminal through which a high-voltage current flows.

  An object of the present invention is to suppress the dielectric breakdown of the resist film due to the current flowing through the connector terminal located on the upper surface of the resist film, and even if the mounting area is small, the connector terminal is independently soldered and soldered. It is to provide a new electric drive device that can perform work.

  A feature of the present invention is that a connector terminal is a connector joint piece that is joined to a wiring terminal over an end surface of a substrate, and a connector balance piece that faces each other so as to maintain balance with the connector joint piece and that makes the connector terminal self-supporting. A connector adhesive piece that is continuously formed from the connector balance piece and that is connected to the wiring pattern on the substrate, and a connector adhesive piece that is continuously formed from the resist film on the substrate beyond the end surface of the substrate. It is composed of a connector separating piece and a connector separating piece, and the connector adhering piece is placed on paste-like solder applied to the wiring pattern on the board to bond and fix the connector terminal to the board.

  According to the present invention, it is possible to suppress the dielectric breakdown of the resist film due to the current flowing through the connector terminal located on the upper surface of the resist film. Further, even if the mounting area is small, the connector terminals can be independently made to be soldered, and the soldering can be performed without using a special jig such as hiring, so that the productivity can be improved.

It is the whole steering device perspective view as an example to which the present invention is applied. FIG. 1 is an overall perspective view of an electric power steering device as an electromechanical integrated electric drive device. It is an exploded perspective view of an electric power steering device. FIG. 4 is a perspective view of the power supply circuit unit shown in FIG. 3. FIG. 4 is a perspective view of the power conversion circuit unit shown in FIG. 3. FIG. 4 is a perspective view of the control circuit unit shown in FIG. 3. It is a perspective view of the cover body shown in FIG. It is the top view which looked at the lid side from the direction of the AA surface shown in FIG. It is sectional drawing seen from the BB surface of FIG. (The electric motor part is omitted.) FIG. 3 is an external perspective view of a power conversion circuit unit according to an embodiment of the present invention. FIG. 11 is a partially enlarged perspective view showing a joint region between the inverter-side connector terminal of the power conversion circuit unit shown in FIG. 10 and the power-supply-side wiring terminal of the power supply circuit unit. It is sectional drawing of the joining area | region of FIG. It is a side view of the inverter side connector terminal shown in FIG. It is an external appearance perspective view of the inverter side connector terminal shown in FIG. It is a partially expanded perspective view which shows the joining area | region of the inverter side connector terminal of the conventional power converter circuit part, and the power supply side wiring terminal of a power supply circuit part. FIG. 16 is a cross-sectional view of the joining region of FIG. 15.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings, but the present invention is not limited to the following embodiments, and various modifications and applications within the technical concept of the present invention. Is also included in the range.

  Before describing the embodiments of the present invention, a configuration of a steering device as an example to which the present invention is applied, and a configuration of an electric power steering device as an electromechanical integrated electric drive device are briefly described with reference to FIGS. 1 and 2. Explained.

  First, a steering device for steering the front wheels of an automobile will be described. The steering system 1 is configured as shown in FIG. A pinion (not shown) is provided at the lower end of the steering shaft 2 connected to a steering wheel (not shown), and this pinion meshes with a rack (not shown) that is long in the lateral direction of the vehicle body. Tie rods 3 for steering the front wheels to the left and right are connected to both ends of the rack, and the rack is covered with a rack housing 4. A rubber boot 5 is provided between the rack housing 4 and the tie rod 3.

  An electric power steering device 6 is provided to assist torque when rotating the steering wheel. That is, the torque sensor 7 that detects the rotation direction and the rotation torque of the steering shaft 2 is provided, and the electric motor unit 8 that applies the steering assist force to the rack via the gear 10 based on the detection value of the torque sensor 7. And an electronic control unit (ECU) unit 9 for controlling the electric motor arranged in the electric motor unit 8. The electric motor unit 8 of the electric power steering device 6 is connected to the gear 10 through three bolts (not shown) on the outer peripheral portion on the output shaft side, and the electronic control unit is provided on the side opposite to the output shaft of the electric motor 8 unit. 9 is provided.

  As shown in FIG. 2, the electric motor unit 8 is composed of a motor housing 11A having a cylindrical portion made of aluminum alloy or the like and an electric motor (not shown) housed in the motor housing 11A. An ECU housing 11B made of aluminum alloy or the like, which is arranged on the opposite side of the axial output shaft of 11A, and an electronic control assembly (not shown) housed in the ECU housing 11B.

  The motor housing 11A and the ECU housing 11B are integrally fixed by fixing bolts at their opposing end faces. The electronic control assembly housed inside the ECU housing 11B includes a power supply circuit section that generates a necessary power supply, a power conversion circuit section that includes a power switching element that includes a MOSFET that drives and controls the electric motor of the electric motor section 8, and the like. A control circuit unit for controlling the power switching element is provided, and the output terminal of the power switching element and the input terminal of the electric motor are electrically connected via a bus bar. Here, the power supply circuit unit, the power conversion circuit unit, and the control circuit unit are separately provided on three different substrates.

  A lid 12 made of synthetic resin, which also serves as a connector terminal assembly, is fixed to the end surface of the ECU housing 11B by fixing bolts 13 (see FIG. 3). The lid 12 is provided with a connector terminal forming portion 12A for power supply, a connector terminal forming portion 12B for a detection sensor, and a control terminal transmitting connector terminal forming portion 12C for transmitting a control state to an external device. The electronic control assembly housed in the ECU housing 11B is supplied with electric power from the power source through the connector terminal forming portion 12A for supplying electric power of the lid body 12 made of synthetic resin, and is operated by the detection sensors. A detection signal such as a state is supplied via the connector forming terminal portion 12B for the detection sensor, and a current control state signal of the electric power steering device is sent out via the connector terminal forming portion 12C for sending the control state.

  In the electric power steering device 6 having the above-described configuration, when the steering shaft 2 is rotated in any direction by operating the steering wheel, the rotation direction and the rotation torque of the steering shaft 2 are changed. Is detected by the torque sensor 7, and the control circuit section calculates the drive operation amount of the electric motor based on the detected value. The electric motor is driven by the power switching element of the power conversion circuit unit based on the calculated drive operation amount, and the output shaft of the electric motor is rotated so as to drive the steering shaft 1 in the same direction as the operation direction. The rotation of the output shaft is transmitted from a pinion (not shown) to a rack (not shown) via the gear 10 to steer the vehicle. Since these configurations and operations are already well known, further description will be omitted.

  As described above, the inverter-side connector terminal soldered to the wiring pattern extends beyond the end face of the substrate to the power-side wiring terminal while being in contact with the upper surface of the resist film from the wiring pattern. Therefore, there is a problem that a high-voltage current flowing through the inverter-side connector terminal that is in contact with the upper surface of the resist film increases the risk of causing dielectric breakdown in the resist film.

  Further, in order to satisfy the demand for miniaturization, it is effective to mount the power supply circuit section and the power conversion circuit section in high density. For this purpose, it is necessary to reduce the mounting area of the connector terminal. However, if the "L" -shaped connector terminal is used, the mounting stability is poor in the mounted state. Therefore, when soldering in the "reflow process", it is not possible to make it self-supporting only with the adhesive force of the paste solder. It is difficult, and further, when the solder melts during the soldering process, there is a phenomenon that the "L" -shaped connector terminal falls. Therefore, it is necessary to make the connector terminal self-supporting by using special employment, which causes a problem that productivity cannot be improved.

  From such a background, the present embodiment proposes an electric drive device (electric power steering device) having the following configuration.

  That is, in the present embodiment, the connector terminal is formed continuously from the connector joint piece, which is joined to the wiring terminal, the connector balance piece that keeps the connector terminal self-supporting while keeping the balance with the connector joint piece. Consists of a connector adhesive piece that is connected to the wiring pattern on the board, and a connector spacing piece that is formed continuously from the connector adhesive piece and that is separated from the resist film on the board and that extends beyond the end surface of the board and continues to the connector joining piece. The connector adhesive piece is placed on a paste-like solder applied to the wiring pattern on the board to bond and fix the connector terminal to the board.

  According to this, it is possible to suppress the dielectric breakdown of the resist film due to the current flowing through the connector terminal located on the upper surface of the resist film. Further, even if the mounting area is small, the connector terminals can be independently made to be soldered, and the soldering can be performed without using a special jig such as hiring, so that the productivity can be improved.

  Hereinafter, the configuration of the electric power steering apparatus according to the embodiment of the present invention will be described, but in the following drawings, the shape of the lid 12 shown in FIG. 2 is different. However, its function is the same.

  FIG. 3 shows an exploded perspective view of the electric power steering device 6. The motor housing 11A normally houses an electric motor. As described above, the motor housing 11A and the ECU housing 11B are made of separate aluminum alloys, but both housings may be the same housing.

  The electronic control unit 9 includes an ECU housing 11B connected to the electric motor in the motor housing 11A on the side opposite to an output shaft (not shown), and a lid 12 connected to the ECU housing 11B by three fixing bolts 13. It is configured. As will be described later, the lid 12 also serves as a connector terminal assembly, and is made of synthetic resin by injection molding. Incidentally, various connector wiring portions are simultaneously embedded in the lid body 12 by insert molding as will be described later.

  A power supply circuit unit 14 is provided in a storage space formed by the ECU housing 11B and the lid 12, and a power conversion circuit unit 15 and a control circuit unit 16 are arranged in the storage spaces of the ECU housing 11B and the motor housing 11A. ing. The power supply circuit unit 14, the power conversion circuit unit 15, and the control circuit unit 16 form an electronic control assembly.

  Inside the ECU housing 11B, a heat dissipation base 46 made of metal such as aluminum or aluminum alloy is arranged. The heat dissipation base 46 is formed integrally with the ECU housing 11B. Further, metal substrates 17 and 18 on which electric components constituting the power supply circuit unit 14 and the power conversion circuit unit 15 are mounted are fixed on both surfaces of the heat dissipation base 46 by single-sided mounting.

  As described above, the heat dissipation base 46 made of aluminum or aluminum alloy having a predetermined thickness is disposed between the metal substrates 17 and 18, and the heat dissipation base 46 functions as a heat dissipation member as described later. It is formed integrally with the ECU housing 11B so that the ECU housing 11B can radiate heat to the outside air. Here, in order to enhance thermal contact between the metal substrates 17 and 18 and the heat dissipation base 46, a heat dissipation function material such as a heat dissipation adhesive, a heat dissipation sheet, and a heat dissipation grease having good thermal conductivity is used. Is intervened between.

  Between the lid 12 and the heat dissipation base 46, a power supply circuit whose main function is to generate a high-voltage DC power supply used in an inverter device that drives an electric motor and a low-voltage DC power supply used in a control circuit such as a microcomputer. The part 14 is arranged.

  As shown in FIG. 4, the power supply circuit unit 14 has a capacitor 19, a coil 20, a switching element 21 including a MOSFET, and a power supply side from a battery on one surface of a metal substrate 17 made of a metal having good heat conductivity such as aluminum. The power supply side connector terminal 22 to which the wiring terminal is connected, the high voltage side connector terminal 23 to which the high voltage side wiring terminal that supplies the high voltage power supply to the power conversion circuit unit 15 is connected, and the low voltage wiring terminal that supplies the low voltage power supply to the control circuit unit 16 Electrical components such as the low-voltage side connector terminal 24 to which is connected are mounted.

  The metal substrate 17 is formed by forming an insulating layer on an aluminum substrate and printing a wiring pattern made of a copper foil on the insulating layer. Parts are electrically connected. The power supply circuit unit 14 uses electric components having a relatively large shape (= tall) such as the capacitor 19, the coil 20, and the connector terminals 22 to 24.

  The connector terminals 22 and 23 are press-fit type connectors and have elasticity toward the inside. Simply inserting the wiring terminals into these connector terminals 22 and 23 makes it easy to connect them to each other without using solder. The connection can be secured. As shown in FIG. 4, the connector terminals 22 and 23 are formed such that both ends of one elongated metal plate are folded inward, and the folded region is folded twice so that both end faces face each other.

  Here, the power supply circuit section 14 has a relatively large mounting area and a sufficient mounting area for the connector terminals 22 and 23, so that a press-fit type connector can be used. Since this press-fit type connector has a wide adhesive surface and good placement stability, there is no risk of tipping over during soldering in the "reflow process".

  Further, the press-fit type connector has elastic end faces 22A and 23A facing each other, and the wiring terminals pushed into these end faces come into strong contact with each other, and the pushing force applied from the wiring terminals pushes the connector terminals 22 and 23. It can be transmitted to the metal substrate 17 via. In the present embodiment, the metal board 17 is not fixed to the heat dissipation base 46 by the fixing screw, but the metal board 17 and the heat dissipation base 46 are fixed by the pushing force applied from the wiring terminals inserted into the connector terminals 22 and 23. It is configured to.

  Then, on the side of the heat dissipation base 46 opposite to the side where the power supply circuit section 14 is located, the power conversion circuit section 15 that executes inverter control whose main function is to drive the electric motor is arranged. In the power conversion circuit unit 15, the metal substrate 18 of the power conversion circuit unit 15 is arranged so as to face the metal substrate 17 of the power supply circuit unit 14 with the heat dissipation base 46 as a boundary.

  The opposing surfaces of the metal substrate 18 of the power conversion circuit unit 15 and the metal substrate 17 of the power circuit unit 14 have substantially the same shape, and heat is easily transferred to the heat dissipation base 46. .. Further, a heat dissipation function material such as a heat dissipation adhesive, a heat dissipation sheet, and a heat dissipation grease having good heat conductivity is interposed between the metal substrates 17 and 18 and the heat dissipation base 46.

  As shown in FIG. 5, the power conversion circuit unit 15 includes a power switching element 25 including a plurality of MOSFETs, and an output connector terminal 26U for outputting the power switching element 25 on a metal substrate 18 made of a metal having a good thermal conductivity such as aluminum. , 26V, 26W, and signal connector terminals 27A to 27D for inputting input signals such as gates, drains, and sources for controlling the switching element 25, and for feeding back the operating status of the switching element 25 to the control circuit unit 16. ing. Further, an inverter-side connector terminal 28 that receives power from the power supply circuit section 14 is also provided. In addition to the six switching elements 25 that control the electric motor, the switching element 25 also includes three fail-safe switching elements 25.

  The output connector terminals 26U, 26V, 26W are press-fit type connectors, and have elasticity toward the inside, and the bus bar connected to the electric motor at the output connector terminals 26U, 26V, 26W. By simply inserting the connector terminals of, mutual connection can be easily secured without using solder.

  On the other hand, a sufficient mounting area cannot be secured in the vicinity of the inverter-side connector terminal 28, and since the inverter-side connector terminal 28 is joined to the wiring terminal in an overlapping manner, the conventional "L" shape shown in FIGS. I was using a connector terminal. The power conversion circuit unit according to this embodiment will be described in detail with reference to FIGS.

  The metal substrate 18 is formed by forming an insulating layer on an aluminum substrate, and forming a wiring pattern made of a copper foil and a resist film on the insulating layer, on which electrical parts are mounted. The respective electric parts are electrically connected. Note that FIG. 5 shows the side on which the above-mentioned electric parts are mounted for easy understanding, but in reality, as shown in FIG. 3, the electric parts are arranged so as to be on the lower side.

  Between the power conversion circuit unit 15 and the motor housing 11A, a control circuit unit 16 having a main function such as switching control of the switching element 25 of the power conversion circuit unit 15 is arranged. A resin substrate mounting boss 29 is formed on the ECU housing 11B toward the motor housing 11A side, and a resin substrate 31 of the control circuit unit 16 is fixed to the resin substrate mounting boss 29 with a mounting bolt.

  As shown in FIG. 6, the control circuit unit 16 has a microcomputer 32 and the like for controlling the switching elements 25 and the like mounted on a resin substrate 31 made of synthetic resin or the like. As shown in FIG. 3, electric components such as peripheral circuits of the microcomputer 32 are arranged on the resin substrate 31, but they are omitted in FIG.

  The resin substrate 31 is arranged at a predetermined distance from the power conversion circuit unit 15, and the electric components of the power conversion circuit unit 15 and the control circuit unit 16 are arranged in the space between them. The control circuit unit 16 and the power conversion circuit unit 15 are connected by the above-mentioned connector terminals 27A to 27D.

  The connector terminals 27A to 27D shown in FIG. 5 have a length that exceeds a predetermined distance between the resin substrate 31 and the power conversion circuit unit 15. The connector terminal 27A is connected to the connection hole 33A of the resin substrate 31, the connector terminal 27B is connected to the connection hole 33B, the connector terminal 27C is connected to the connection hole 33C, and the connector terminal 27D is connected to the connection hole 33D. It is like this. The connection hole 33E formed in the control board 31 is connected to a control-side connector terminal for signal transmission and low-voltage power supply, which is buried in an insulating region of the lid 12 described later.

  In this way, the power supply circuit unit 14, the heat dissipation base 46, the power conversion circuit unit 15, and the control circuit unit 16 are arranged in this order from the lid 12 toward the motor housing 11A. By disposing the control circuit unit 16 at a distance from the power supply circuit unit 14 as described above, it is possible to provide a stable power supply to the control circuit unit 16 after removing power supply noise.

  Returning to FIG. 3, the lid body 12 in which the wiring portion connected to each connector terminal is embedded covers the opening of the ECU housing 11B, and like the one shown in FIG. In addition, a terminal forming portion 12A for power supply, a terminal forming portion 12B for a detection sensor, and a terminal forming portion 12C for transmitting a control state for transmitting a control state to an external device are provided. The terminal forming portion 12B and the terminal forming portion 12C may be integrally formed. Then, power is supplied to the power supply circuit unit 14 from a power supply (not shown) via these terminal forming units 12A to 12C. Similarly, signals from the detection sensor and the like are input to the control circuit unit 16.

  Next, the structure of the lid body 12 will be described. As shown in FIG. 7, the lid body 12 is made of synthetic resin, and the lid body 12 also serves as a wiring terminal assembly. Section and its wiring terminals.

  First of all, the power source side wiring portion, which is a wiring portion for supplying power, which connects the terminal forming portion 12A connected to the external power source (= vehicle battery) and the power source circuit portion 14, is embedded in the lid body 12, and The power supply side wiring terminal 34 is exposed from the lid 12. The power supply side wiring terminals 34 are located inside the side peripheral surface of the lid body 12.

  The power supply side wiring terminal 34 is connected to the power supply side connector terminal 22 of the power supply circuit section 14, and the connection is simply completed by inserting the power supply side wiring terminal 34 into the press-fit type power supply side connector terminal 22. To do. The power source side wiring terminal 34 is inserted into the press-fit type power source side connector terminal 22 and has a function of strongly pressing the metal substrate 17 against the heat dissipation base 46.

  Next, a high-voltage side wiring portion, which is a wiring portion for supplying electric power, which connects the power supply circuit portion 14 and the power conversion circuit portion 15, is embedded in the lid 12. Both ends of the high voltage side wiring portion are formed as a high voltage side wiring terminal 35 and an inverter side wiring terminal 36 and are exposed from the lid 12. One of the high voltage side wiring terminals 35 is connected to the high voltage side connector terminal 23 of the power supply circuit section 14, and the other inverter side wiring terminal 36 is connected to the inverter side connector terminal 28 of the power conversion circuit section 15.

  The high-voltage side wiring terminal 35 is connected to the high-voltage side connector 23 of the power supply circuit unit 14. Simply inserting the high-voltage side wiring terminal 35 into the press-fit type high-voltage side connector terminal 23 makes it easy to use without using solder. The connection is completed. The high voltage side wiring terminal 35 is inserted into the press-fit type high voltage side connector 23, and has a function of strongly pressing the metal substrate 17 against the heat dissipation base 46.

  The inverter-side wiring terminal 36 is connected to the inverter-side connector terminal 28 of the power conversion circuit unit 15, and the connection is completed by TIG welding the inverter-side wiring terminal 36 and the inverter-side connector terminal 28. Is.

  The cross-sectional shape of the high-voltage side wiring portion is between the high-voltage side wiring terminal 35 and the inverter-side wiring terminal 36, and the inverter-side wiring terminal has a longer U-shape. This long portion is embedded in a synthetic resin forming the lid body 12 to form a high voltage side insulating region portion 41. The high voltage side insulating region portion 41 has the metal substrates 17 and 18 and the heat dissipation base as shown in FIG. The insertion portion 43 formed in 46 is inserted and extends to the power conversion circuit portion 15. Further, the high voltage side insulating region portion 41 constituting the high voltage side wiring portion is located between the outer peripheral side of the metal substrates 17, 18 and the heat dissipation base 46 and the inner side peripheral surface of the lid 12.

  Next, the low-voltage side wiring portion, which is a wiring portion for supplying electric power, which connects the power supply circuit portion 14 and the control circuit portion 16, is embedded in the lid body 12. Both ends of the low voltage side wiring portion are formed as a low voltage side wiring terminal 37 and a control side wiring terminal 38 and are exposed from the lid 12. One low voltage side wiring terminal 37 is connected to the low voltage side connector terminal 24 of the power supply circuit section 14, and the other control side wiring terminal 38 is connected to the connection hole 33E of the control circuit section 16.

  Further, a signal transmission wiring portion for signal transmission, which is connected to the connector terminal forming portion 12B for the detection sensor and the connector terminal forming portion 12C for sending out the control state, is embedded in the lid body 12 adjacent to the low voltage side wiring portion. Then, the control-side wiring terminal 39 is exposed from the lid 12.

  The low-voltage side wiring terminal 37 is connected to the low-voltage side connector terminal 24 of the power supply circuit unit 14, and the connection is completed simply by fitting the low-voltage side wiring terminal 37 to the socket-type low-voltage side connector terminal 24. is there. The control-side wiring terminal 38 and the control-side wiring terminal 39 for signal transmission are connected to the connection hole 33E of the control circuit unit 16, and the control-side wiring terminals 38 and 39 and the connection hole 33E are soldered. The connection is completed by joining them.

  Next, details of the configuration of the electronic control assembly housed in the ECU housing 11B will be described with reference to FIGS. 8 and 9.

  8: is the figure which looked at the direction of the cover 12 from the AA surface shown in FIG. 3, and has shown the plane of the power conversion circuit part 15. As shown in FIG. The detailed configuration of the power conversion circuit unit 15 is as shown in FIG. Insertion portions 40 and 43 are formed between the metal substrate 18 and the ECU housing 11B.

  The insertion portion 40 is a linear cutout formed on the outer periphery of the metal substrate 18, and the low-voltage side insulating region portion 42 extends to the control circuit portion 16 side through the insertion portion 40. The linear "cutout" is formed in this manner because the number of wiring portions passing through the low voltage side insulating region portion 42 is large and the area of the "cutout" is increased to insert the low voltage side insulating region portion 42. Is. Of course, it goes without saying that the metal substrate 17 and the heat dissipating base 46 are also formed with insertion portions that match the insertion portions 40.

  Similarly, the insertion portion 43 is a “cutout” formed on the outer periphery of the metal substrate 18, and the high-voltage side insulating region portion 41 described above extends through the insertion portion 43 toward the power conversion circuit portion 15 side. Of course, it goes without saying that the metal substrate 17 and the heat dissipation base 46 are also provided with insertion portions that match the insertion portions 43 formed on the metal substrate 18.

  Next, a cross section of the electric power steering apparatus viewed from the BB plane of FIG. 8 will be described based on FIG. 9, but in FIG. 9, the electric motor portion is omitted.

  In FIG. 9, a high voltage side insulating region 41 made of synthetic resin extends from the inner bottom surface of the lid 12 toward the control circuit 16 side. The high-voltage side insulating region portion 41 is inserted through the insertion portion 44 provided on the outer peripheral portion of the metal substrate 17, the insertion portion 43 provided on the outer peripheral portion of the metal substrate 18, and the insertion portion 47 provided on the heat dissipation base 46, and the power conversion circuit. It extends to the part 15. The insertion portions 43 and 44 of the metal substrates 17 and 18 are formed between the outer peripheral surfaces of the metal substrates 17 and 18 and the side peripheral surface of the lid 12, and the insertion portion 47 of the heat dissipation base 46 is formed on the heat dissipation base 46. It is an insertion hole formed inside the outer peripheral side.

  A high-voltage side wiring portion 45 is embedded inside the high-voltage side insulating region portion 41. A high-voltage side wiring terminal 35 is formed on one side of the high-voltage side wiring portion 45 and an inverter-side wiring terminal 36 is formed on the other side. Has been done. In this way, the high-voltage side insulating region section 41 ensures insulation between the high-voltage side wiring section 45, the respective metal substrates 17 and 18, and the heat dissipation base 46.

  The high-voltage side wiring terminal 45 including the high-voltage side wiring terminal 35 and the inverter-side wiring terminal 36 is formed in a U-shape, and the high-voltage side connector terminal 23 of the power supply circuit section 14 and the inverter of the power conversion circuit section 15 are formed. Since the side connector terminals 28 are provided in the opposite direction, they can be connected to each other.

  Therefore, when fixing the lid 12 to the ECU housing 11B, the high-voltage side wiring terminal 35 is connected by inserting it into the press-fit type high-voltage side connector terminal 23, and the inverter side wiring terminal 36 is connected to the inverter side connector terminal 28. It can be connected by welding. At this time, the control circuit section 16 is not provided, and the TIG welding torch can be easily brought close to the inverter side wiring terminal 36 and the inverter side connector terminal 28.

  As described with reference to FIGS. 15 and 16, the conventional inverter-side connector terminal soldered to the wiring pattern exceeds the end face of the substrate while contacting the upper surface of the resist film from the wiring pattern, and the inverter-side wiring It is designed to extend to the terminal. Therefore, there is a problem that a high-voltage current flowing through the inverter-side connector terminal that is in contact with the upper surface of the resist film increases the risk of causing dielectric breakdown in the resist film.

  In addition, in the area near the inverter-side connector terminal, a sufficient mounting area cannot be secured because the insertion portion is located, etc., and conventionally, an "L" -shaped connector terminal has been used. This "L" -shaped inverter-side connector terminal has poor mounting stability in the mounted state, and when soldering in the "reflow process", it is self-sustaining only with the adhesive force of the paste-shaped solder. This is difficult, and if the solder melts during the soldering process, the “L” -shaped connector terminal will fall.

  Therefore, in this embodiment, the inverter-side connector terminals as shown in FIGS. 10 to 14 are adopted.

  The power conversion circuit unit shown in FIG. 10 is a new power conversion circuit unit 15N according to this embodiment. As shown in FIG. 10, the power conversion circuit unit 15N includes a power switching element 25N composed of a plurality of MOSFETs and an output connector terminal 26U for outputting the power switching element 25N composed of a plurality of MOSFETs on a metal substrate 18N composed of a metal having good thermal conductivity such as aluminum. -N, 26V-N, 26W-N, and a signal connector terminal 27A for feeding back an input of an input signal such as a gate, a drain, and a source for controlling the switching element 25N and an operating condition of the switching element 25N to the control circuit unit 16. -N to 27D-N, etc. are installed. The switching element 25N is provided with three fail-safe switching elements 25N in addition to the six switching elements 25N for controlling the electric motor.

  The output connector terminals 26U-N, 26V-N, and 26W-N are press-fit type connectors as in FIG. 5, and have elasticity toward the inside. -By simply inserting the connector terminals of the bus bar connected to the electric motor into N, 26V-N, and 26W-N, mutual connection can be easily secured without using solder.

  Further, the area where the output connector terminals 26U-N, 26V-N, and 26W-N are mounted has a relatively large mounting area, and the output connector terminals 26U-N, 26V-N, and 26W-N are mounted. Since a sufficient area can be obtained, a press fit type connector can be used. Since this press-fit type connector has a wide adhesive surface and good placement stability, there is no risk of tipping over during soldering in the "reflow process".

  Here, in the metal substrate 18N, an insulating film is formed on a metal substrate, a wiring pattern and a resist film are formed on the insulating film, and various electric and electronic parts are further mounted on the wiring pattern. is there.

  In the present embodiment, as shown in FIG. 10, two inverter-side connector terminals 28N connected to the power supply side and the ground side are placed on the metal substrate 18N. This inverter-side connector terminal 28N is formed by bending an elongated flat plate and has a cross section formed into a substantially "U" shape as shown in FIG. 13, and each bent surface is formed into a flat shape. ing. The inverter-side connector terminal 28N shown in FIGS. 11 to 14 is slightly modified in shape from the inverter-side connector terminal 28N shown in FIG.

  As shown in FIGS. 11 to 14, the inverter-side connector terminal 28N is a connector joint piece 28N-C that is joined to the inverter-side wiring terminal 36 over the end surface 18NE of the metal substrate 18N, and the connector joint piece 28N-C. A connector balance piece 28N-B that faces each other so as to keep the inverter-side connector terminal 28N self-standing, and a connector formed continuously from the connector balance piece 28N-B and connected to a wiring pattern on the metal substrate 18N. It is formed continuously from the adhesive piece 28N-A and the connector adhesive piece 28N-A, and continues to the connector joint piece 28N-C beyond the end surface 18NE of the metal substrate 18N so as to be separated from the resist film 48 on the metal substrate 18N. It is composed of connector spacing pieces 28N-D.

  Then, the connector adhesive piece 28N-A is placed on the paste solder applied to the wiring pattern 49 (see FIG. 11) on the metal substrate 18N, and the inverter-side connector terminal 28N is attached to the metal substrate 18N by the "reflow process". It is glued and fixed. Since the connector adhesive piece 28N-A is flat, it can be used as a suction surface when the inverter-side connector terminal 28N is placed on the wiring pattern 49 by an automatic machine.

  FIG. 11 shows the vicinity of the joint between the inverter side wiring terminal 36 and the inverter side connector terminal 28N of the power conversion circuit section 15N. In FIG. 11, one of the inverter-side connector terminals 28N is omitted for easy understanding. In FIGS. 11 and 12, a resist film 48 is formed on the surface of the metal substrate 18N, and a wiring pattern 49 is exposed from the resist film 48. On the wiring pattern 49, the connector adhesive piece 28N-A of the inverter-side connector terminal 28N is placed and adhered and fixed by solder.

  Since the flat plate portion of the inverter side wiring terminal 36 and the flat plate-shaped connector joint piece 28N-C of the inverter side connector terminal 28N are superposed and joined, the connector joint piece 28N-C of the inverter side connector terminal 28N is the inverter. It is arranged so as to be close to the flat plate portion of the side wiring terminal 36. In this way, since the connector joint piece 28N-C is connected close to the flat plate portion of the inverter-side wiring terminal 36, the connector joint piece 28N-C connects the end surface 18NE of the metal substrate 18N of the power conversion circuit unit 15N. It is configured to extend beyond the length g to the inverter side wiring terminal 36.

  Further, in the present embodiment, the connector adhesive pieces 28N-A and the connector joint pieces 28N-C are connected by the connector spacing pieces 28N-D. The connector separating piece 28N-D extends obliquely upward from the connector adhering piece 28N-A toward the connector joining piece 28N-C, and is different from the resist film 48 existing between the end surface 18NE of the metal substrate 18N. The resist film 48 is formed so as not to come into contact with the resist film 48 and gradually move away from the resist film 48. Therefore, a separation space Sa having a triangular cross section is formed between the connector separation pieces 28N-D and the resist film 48.

  With such a configuration, even if a high-voltage current flows through the inverter-side connector terminal 28N, the insulating space between the connector spacing pieces 28N-D and the resist film 48 is improved due to the existence of the spacing space Sa. The dielectric breakdown of the film 49 is suppressed. The connector spacing piece 28N-D is configured to extend obliquely upward to form the spacing space Sa. However, the connector spacing piece 28N-D rises vertically from the connector bonding piece 28N-A, and the connector joining piece 28N. The separated space Sa can be formed even in a shape extending in the lateral direction toward −C.

  Here, the bonding size of the connector bonding piece 28N-A is determined to be substantially the same as that of the conventional "L" -shaped inverter-side connector terminal. Therefore, even if the mounting area is the same as the conventional one, it can be mounted sufficiently. As described above, in the connector terminal having the shape as shown in FIGS. 13 and 14, since the connector joining piece 28N-C and the connector balancing piece 28N-B are formed, the placement stability is excellent and the self-standing It is possible to In this case, the connector bonding piece 28N-A is located on the extension line of the center of gravity of the connector joining piece 28N-C and the connector balancing piece 28N-B.

  The connector terminal 28N is placed on a predetermined wiring pattern 49 of the metal board 18N and soldered as shown in FIG. Therefore, when soldering is performed in the "reflow process", the inverter-side connector terminal 28N has good placement stability, and the inverter-side connector terminal 28N does not fall over even if the solder melts in the soldering process. .. Therefore, it is not necessary to make the inverter-side connector terminal self-supporting by using special employment, and the productivity can be improved.

  Further, between the connector adhering piece 28N-A and the connector joining piece 28N-C of the inverter-side connector terminal 28N according to the present embodiment, a connector separating piece 28N-D inclined upward as viewed from the connector adhering piece 28N-A is formed. Has been done. This connector spacing piece 28N-D has a function of forming a spacing space Sa that suppresses dielectric breakdown and a function of buffering stress by bending when an excessive load acts on the connector joining piece 28N-C. I have it.

  That is, the connector spacing piece 28N-D has a function of relieving the stress at the time of TIG welding. The tip of the inverter-side connector terminal 28N and the high-voltage side wiring terminal 36 are overlapped with each other and the tips are TIG-welded. After the welding, a stress is generated between the terminals, but the connector spacing pieces 28N-D should alleviate the stress. Will be able to.

  Further, as can be seen from FIGS. 12 and 14, projecting portions 50 projecting outward from the side surfaces are formed on both side surfaces of the connector joint surface 28N-C, and in accordance therewith, projecting portions are also formed on the inverter side wiring terminal 36. 51 is formed. As shown in FIG. 12, the welded portion W is formed by TIG welding at the tip of the flat plate portion of the connector joint piece NC and the inverter side wiring terminal 36, and the molten metal generated by this welding is the metal substrate 18N or There is a possibility that it will flow down to the high-voltage side wiring part 45 side. Therefore, the protrusions 50 and 51 are formed to prevent the molten metal from flowing down, and to prevent the molten metal from flowing down to the metal substrate 18N and the high-voltage side wiring portion 45 side.

  Further, on both side surfaces of the connector joint surface 28N-C, a recessed portion 52 is formed which is recessed inward from the side surface. At the time of TIG welding, it is necessary to bring the connector joint piece NC and the flat plate portion of the inverter side wiring terminal 36 close to each other, so that the receding portion 52 is formed to facilitate deformation. Further, although stress is generated between the terminals after welding, the stress can be relieved by the recess 52.

  Further, in the vicinity of the center on both sides of the connector bonding piece 28N-A, projecting portions 53 projecting outward from the side surfaces are formed. The connector adhesive piece 28N-A is soldered to the wiring pattern 49, and a board appearance inspection device is used to observe the solder state (fillet state or the like). Then, by observing the state of the solder in the vicinity of the protruding portion 53, it is possible to inspect defects such as defective adhesion.

  Furthermore, since the connector balancing piece 28N-B is newly formed, it is easy to dissipate the heat from the metal substrate 18N, and as a result, it is possible to contribute to dissipating the heat of the power conversion circuit (inverter circuit). is there.

  In the present embodiment, the inverter-side connector terminal of the power conversion circuit section has been described, but it goes without saying that the present invention can be applied to other connector terminals and connector terminals of the power supply circuit section.

  As described above, according to the present invention, a connector terminal is a connector joining piece that is joined to a wiring terminal over the end surface of a substrate, and a connector that makes the connector terminal stand face-to-face so as to maintain balance with the connector joining piece. A balance piece and a connector adhesive piece that is continuously formed from the connector balance piece and is connected to the wiring pattern on the substrate, and an end surface of the substrate that is continuously formed from the connector adhesive piece and is separated from the resist film on the substrate The connector connecting piece is connected to the connector separating piece, and the connector adhering piece is placed on paste-like solder applied to the wiring pattern on the board to bond and fix the connector terminal to the board.

  According to this, it is possible to suppress the dielectric breakdown of the resist film due to the current flowing through the connector terminal located on the upper surface of the resist film. Further, even if the mounting area is small, the connector terminals can be independently made to be soldered, and the soldering can be performed without using a special jig such as hiring, so that the productivity can be improved.

  It should be noted that the present invention is not limited to the above-described embodiment, and various modifications are included. For example, the above-described embodiments have been described in detail in order to explain the present invention in an easy-to-understand manner, and are not necessarily limited to those including all the configurations described. Further, a part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment. Further, it is possible to add / delete / replace other configurations with respect to a part of the configurations of the respective embodiments.

  6 ... Electric power steering device, 11A ... Motor housing, 11B ... ECU housing, 12 ... Lid, 12A-12C ... Connector terminal part, 14 ... Power circuit part, 15 ... Power conversion circuit part, 16 ... Control circuit part, 17 , 18 ... Metal substrate, 19 ... Capacitor, 20 ... Coil, 21 ... Switching element, 22 ... Power supply side connector terminal, 23 ... High voltage side connector terminal, 24 ... Low voltage side connector terminal, 25 ... Switching element, 26U, 26V, 26W ... output connector terminal, 28 ... inverter side connector terminal, 28N ... inverter side connector terminal, 28N-A ... connector adhesive piece, 28N-B ... connector balancing piece, 28N-C ... connector joining piece, 28N-D ... connector separating piece , 34 ... Power source side wiring terminal, 35 ... High voltage side wiring terminal, 36 ... Inverter side wiring terminal, 37 ... Low voltage side wiring terminal, 41 ... High voltage side insulating area portion, 42 ... Low voltage side insulating area portion, 43, 44, 47 ... Insertion part, 45 ... High-voltage side wiring part, 46 ... Heat dissipation base, 48 ... Resist film, 49 ... Wiring pattern, 50, 51 ... Projection part, 52 ... Receding part, 53 ... Projection part.

Claims (7)

An electric motor that drives a mechanical system control element, and an electronic control device that is arranged on the opposite side of the output shaft of the electric motor and that controls the electric motor,
The electronic control unit,
An ECU housing coupled to a motor housing containing the electric motor, and an electronic control assembly housed inside the ECU housing for driving and controlling the electric motor,
The electronic control assembly has at least a power supply circuit unit mounted on a power supply side substrate having a main function of generating a power supply, and a power conversion unit mounted on an inverter side substrate having a main function of driving the electric motor. It consists of a circuit part and
At least the connector terminal of the inverter-side substrate, which is connected to the wiring terminal of the wiring unit that connects the power supply circuit unit and the power conversion circuit unit,
From the connector balance piece, a connector joint piece that is joined to the wiring terminal beyond the end surface of the inverter-side substrate, a connector balance piece that faces the connector joint piece so as to keep the connector terminal self-standing A connector adhesive piece that is continuously formed and is connected to the wiring pattern on the inverter-side substrate, and a connector adhesive piece that is continuously formed from the connector-adhesive piece and is separated from the resist film on the inverter-side substrate. It is composed of a connector spacing piece that continues the connector joining piece beyond the end face of the board,
An electric drive device in which the connector adhesive piece is adhered and fixed to the wiring pattern by soldering . An electric motor that drives a mechanical system control element, and an electronic control device that is arranged on the opposite side of the output shaft of the electric motor and that controls the electric motor,
The electronic control unit,
An ECU housing coupled to a motor housing containing the electric motor, and an electronic control assembly housed inside the ECU housing for driving and controlling the electric motor,
The electronic control assembly has a power supply circuit unit mounted on a power supply side metal substrate having a main function of generating a power supply, and a power conversion circuit unit mounted on an inverter side metal substrate having a main function of driving the electric motor. And a control circuit unit mounted on a resin substrate whose main function is to control the power conversion circuit unit, and
An inverter-side connector terminal of the power conversion circuit unit connected to a power-supply-side wiring terminal extending from the power supply circuit unit,
A connector joint piece joined to the power supply side wiring terminal beyond the end face of the inverter side metal substrate; From a resist film on the inverter-side metal substrate, a connector adhesive piece continuously formed from the connector balance piece and connected to a wiring pattern on the inverter-side metal substrate, and continuously formed from the connector adhesive piece The connector-separating piece that is continuous with the connector joining piece beyond the end surface of the inverter-side metal substrate so as to be separated,
An electric drive device, wherein the connector adhesive piece is adhered and fixed to the wiring pattern by soldering . The electric drive device according to claim 2,
The connector spacing pieces, the electric drive device characterized in that it is formed in a shape you inclined obliquely from said connector adhesive strip gradually away direction from the resist film toward said connector joining pieces. The electric drive device according to claim 3,
The cross section of the inverter-side connector terminal is formed in a substantially “U” shape by the connector joining piece, the connector spacing piece, the connector adhesive piece, and the connector balancing piece. Drive. The electric drive device according to claim 2 ,
It said power supply side wiring terminal and the connector joining pieces are welded at the tip end is formed into a flat plate shape, to the power side wiring terminal and the connector joining pieces of the more welded portions inverter side metal substrate, melting An electric drive device, characterized in that a protrusion for blocking the flow of metal is formed. The electric drive device according to claim 1 or 2,
The electric drive device is characterized in that the connector joining piece is formed in a flat plate shape, and a recessed inward portion for facilitating deformation is formed on both side surfaces of the connector joining piece. The electric drive device according to claim 1 or 2,
The said connector adhesive strips, an electric drive unit, characterized in that the protrusion for observing the state of the solder is formed.

Images