JP7041541B2 - Electric drive device and electric power steering device - Google Patents

Description

The present invention relates to an electric drive device and an electric power steering device, and more particularly to an electric drive device and an electric power steering device having a built-in electronic control device.

In the general industrial machinery field, mechanical control elements are driven by electric motors, but recently, electronic control units including semiconductor elements that control the rotational speed and rotational torque of electric motors are electrically operated. So-called mechanical and electrical integrated electric drive devices that are integrated into motors are beginning to be adopted.

As an example of an electric drive device integrated with mechanical and electrical equipment, for example, in an electric power steering device of an automobile, the rotation direction and rotation torque of the steering shaft that is rotated by the driver operating the steering wheel are detected, and the rotation torque is detected. 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 is configured to generate steering assist torque. In order to control this electric motor, an electronic control unit (ECU: Electronic Control Unit) is provided in the power steering device.

As a conventional electric power steering device, for example, the one described 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 unit and an electronic control unit. The electric motor of the electric motor unit is housed in a motor housing having a tubular portion made of an aluminum alloy or the like, and the substrate on which the electronic components of the electronic control unit are mounted is different from the output shaft in the axial direction of the motor housing. It is attached to a heat sink that functions as an ECU housing located on the opposite side.

The substrate attached to the heat sink includes a power supply circuit unit, a power conversion circuit unit having a power switching element such as a MOSFET for driving and controlling an electric motor, or an IGBT, and a control circuit unit for controlling the power switching element. The output terminal of the element and the input terminal of the electric motor are electrically connected via a bus bar.

The electronic control unit attached to the heat sink is supplied with electric power from a power source via a connector case made of synthetic resin, and is supplied with a detection signal such as an operating state from detection sensors. The connector case functions as a lid, and is fixed so as to seal and close the heat sink, and is fixed to the outer peripheral surface of the heat sink by a fixing screw.

In addition to this, as an electric drive device integrated with an electronic control device, an electric brake, an electric hydraulic controller for various hydraulic control, and the like are known, but in the following description, the electric power steering device is represented. explain.

JP-A-2015-134598

By the way, in the electric power steering device having the configuration as described in Patent Document 1, the motor housing, the heat sink, and the connector case are configured to be jointly tightened by a fixing screw through which a fixing portion formed so as to project to the outer peripheral side is inserted.

A sealing member such as an O-ring is used between the motor housing and the heat sink, or between the heat sink and the connector case for liquidtightness. Further, it is fixed between the motor housing and the heat sink, or between the heat sink and the connector case by a fixing screw. When the heat sink is not used, an O-ring is interposed between the motor housing and the connector case and fixed with a fixing screw.

However, in automobiles, it is often used in areas where salt damage is significant, and in the case of a liquid-tight seal structure with only O-rings, there is a substantial fitting gap up to the area where the O-rings are located. Will be formed. For this reason, salt water may enter the fitting gap, corrode the O-ring storage portion, and in the worst case, cause poor liquidtightness, and the salt water may infiltrate into the inside to impair electrical reliability.

Therefore, in order to solve such a problem, the applicant arranges an electronic control unit on the end face portion of the motor housing, for example, as shown in FIG. 13, and the open end of the metal cover covering the electronic control unit is set on the end face portion of the motor housing. We are proposing a configuration for joining via a liquid sealant.

In FIG. 13, a motor housing side annular groove 52 composed of an annular groove 51 extending in the axial direction is formed on the outer peripheral portion of the end surface of the motor housing 50, and the annular groove 51 of the motor housing side annular groove 52 is filled with a liquid sealant 53. Is filled. The metal cover-side annular tip portion 55, which is the open end of the metal cover 54, is housed in the liquid sealant 53 and is immersed in the liquid sealant 53, and the liquid sealant 53 is cured in the drying and curing steps. As a result, the annular groove portion 52 on the motor housing side and the annular tip portion 55 on the metal cover side are liquidtightly bonded by the liquid sealant 53.

Here, the metal cover 54 is formed so as to cover all of the electronic control units fixed to the end face side of the motor housing 50 and a part of the resin connector for connecting the electronic control units to external devices, and is electronically controlled. The part is designed to be protected mechanically and electrically. This also applies to the present embodiment described later.

The metal cover 54 has a closed structure except for the opening to be adhered to the annular groove portion 52 on the motor housing side so that a liquid such as water does not enter the inside. Therefore, in the case of sealing with the liquid sealant 53, after the liquid sealant 53 is filled in the annular groove 51 of the motor housing side annular groove portion 52, the metal cover side annular tip portion 55 of the metal cover 54 is inserted into the annular groove 51. Therefore, it is immersed in the liquid sealant 53.

However, even after the metal cover-side annular tip portion 55 of the metal cover 54 is inserted into the annular groove 51 and immersed in the liquid sealant 53, the metal cover 54 is continuously inserted into the annular groove 51. In this case, since the end face portion of the motor housing 50 is configured to liquidally partition the inside of the metal cover 54 that covers the electronic control unit, the air remaining inside the metal cover 54 is compressed. The compressive pressure of the air may push the liquid sealant 53 to the outside, resulting in an incomplete sealing function. Therefore, there is a possibility that water or the like may infiltrate into the metal cover 54 from a portion where the sealing function is incomplete and corrode the electronic control unit, and further, this corrosion may cause an electric short circuit.

Therefore, there is a demand for an electric drive device and an electric power steering device that meet such problems. A main object of the present invention is to provide a novel electric drive device and an electric power steering device with improved electrical reliability.

The feature of the present invention is to provide an electronic control unit for controlling the electric motor and a connector for connecting the electronic control unit and an external device on the end face portion of the motor housing on the opposite side of the output portion of the rotary shaft of the electric motor. An annular groove on the motor housing side consisting of an annular groove is formed on the outer peripheral surface of the end surface of the motor housing, and the annular groove on the motor housing side is formed at the open end of the cover that is liquid-tightly engaged with the outer periphery of the connector to cover the electronic control unit. With the annular tip on the cover side facing the annular groove of the groove and the annular tip on the cover side facing the annular groove on the motor housing side, the annular groove on the motor housing side and the annular tip on the cover side are arranged. A liquid sealant is filled between them, and a connection hole is formed in the connector to connect the inside of the cover and the external environment area.

According to the present invention, by forming a connection hole in the connector for connecting the inside of the cover and the external environment area, the compressed pressure of the air in the cover generated when the cover is attached can be released to the external environment area. It is possible to prevent the liquid sealant from being pushed out. Therefore, since this sealing function can be sufficiently obtained, it is possible to improve the electrical reliability.

It is an overall perspective view of the steering apparatus as an example to which this invention is applied. It is a perspective view which shows the whole shape of the electric power steering apparatus which becomes embodiment of this invention. It is an exploded perspective view of the electric power steering apparatus shown in FIG. It is a perspective view of the motor housing shown in FIG. FIG. 3 is a cross-sectional view of the motor housing shown in FIG. 4 in a cross-sectional direction in the axial direction. It is a perspective view which shows the state which the power conversion circuit part was placed and fixed in the motor housing shown in FIG. It is a perspective view which shows the state which the power supply circuit part was placed and fixed in the motor housing shown in FIG. It is a perspective view which shows the state which the control circuit part was placed and fixed in the motor housing shown in FIG. 7. It is a perspective view which shows the state which the connector terminal assembly is placed and fixed in the motor housing shown in FIG. It is an external view of the electric power steering apparatus which becomes an embodiment of this invention after crimping and fixing a metal cover to a motor housing. It is sectional drawing of the main part of the electric power steering apparatus shown in FIG. It is sectional drawing which shows the enlarged cross section of the other joint part by a liquid sealant. It is sectional drawing which shows the enlarged cross section of the joint part by the liquid sealant of a motor housing and a metal cover for demonstrating the subject of this invention.

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 are included in the technical concept of the present invention. Is also included in that range.

Before explaining the embodiment of the present invention, the configuration of the steering device as an example to which the present invention is applied will be briefly described with reference to FIG.

First, a steering device for steering the front wheels of an automobile will be described. The steering device 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 left-right direction of the vehicle body. Tie rods 3 for steering the front wheels in the left-right direction 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 the torque when rotating the steering wheel. That is, a 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 steering assist force to the rack via the gear 10 based on the detection value of the torque sensor 7. And an electronic control device (ECU) unit 9 for controlling the electric motor arranged in the electric motor unit 8. In the electric motor unit 8 of the electric power steering device 6, three locations on the outer peripheral portion on the output shaft side are connected to the gear 10 via screws (not shown), and the electronic control unit 9 is on the side opposite to the output shaft of the electric motor 8 unit. Is provided.

In the electric power steering device 6, when the steering shaft 2 is rotated in either direction by operating the steering wheel, the torque sensor 7 determines the rotation direction and rotation torque of the steering shaft 2. It is detected, and the control circuit unit 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 a gear 10, and the automobile is steered. Since these configurations and actions are already well known, further description thereof will be omitted.

Again, in FIG. 13, the metal cover 54 has a closed structure except for the opening to be adhered to the annular groove portion 52 on the motor housing side so that a liquid such as water does not enter the inside. Therefore, in the case of sealing with the liquid sealant 53, after the liquid sealant 53 is filled in the annular groove 51 of the motor housing side annular groove portion 52, the metal cover side annular tip portion 55 of the metal cover 54 is inserted into the annular groove 51. Therefore, it is immersed in the liquid sealant 53.

However, even after the metal cover-side annular tip portion 55 of the metal cover 54 is inserted into the annular groove 51 and immersed in the liquid sealant 53, the metal cover 54 is continuously inserted into the annular groove 51. Therefore, the air remaining inside the metal cover 54 is compressed, and the compressive pressure may push the liquid sealant 53 to the outside, resulting in incomplete sealing function. Therefore, there is a possibility that water or the like may infiltrate into the metal cover 54 from a portion where the sealing function is incomplete and corrode the electronic control unit, and further, this corrosion may cause an electric short circuit.

Against this background, the present embodiment proposes an electric power steering device having the following configuration.

In the present embodiment, an electronic control unit that controls the electric motor is located on the end face portion of the metal motor housing on the opposite side of the output unit of the rotary shaft of the electric motor, and a resin material that connects the electronic control unit and an external device. A metal cover that covers the electronic control unit by providing a connector and forming an annular groove on the motor housing side consisting of an annular groove on the outer peripheral surface of the end surface of the motor housing and liquidally engaging with the outer periphery of the resin connector. A metal cover-side annular tip facing the annular groove of the motor housing-side annular groove is formed at the open end, and the metal cover-side annular tip is arranged facing the motor housing-side annular groove on the motor housing side. A liquid sealant is filled between the annular groove portion and the annular tip portion on the metal cover side, and a connection hole for connecting the inside of the metal cover and the external environment area is formed in the resin connector.

According to this, by forming a connection hole connecting the inside of the metal cover and the external environment area in the resin connector, the compressed pressure of the air inside the metal cover generated when the metal cover is attached can be released to the external environment area. This can prevent the liquid sealant from being pushed out. Therefore, since this sealing function can be sufficiently obtained, it is possible to improve the electrical reliability.

Hereinafter, a specific configuration of the electric power steering device according to the embodiment of the present invention will be described in detail with reference to FIGS. 2 to 11.

FIG. 2 is a drawing showing the overall configuration of the electric power steering device according to the present embodiment, and FIG. 3 is a drawing in which the components of the electric power steering device shown in FIG. 2 are disassembled and viewed from an oblique direction. 4 to 9 are drawings showing a state in which each component is assembled according to the assembly order of each component. Therefore, in the following description, the description will be given with reference to each drawing as appropriate.

As shown in FIG. 2, the electric motor portion 8 constituting the electric power steering device is a motor housing 11 having a tubular portion made of an aluminum-based metal such as aluminum or an aluminum alloy, and an electric motor unit (not shown) housed therein. The electronic control unit 9 is composed of a motor and is made of aluminum, an aluminum metal such as an aluminum alloy, or an iron metal arranged on the side opposite to the axial output shaft of the motor housing 11. It is composed of a metal cover 12 and an electronically controlled assembly (not shown) housed therein.

The motor housing 11 and the metal cover 12 are formed on the opposite end faces thereof and are integrally fixed in the fixing region portion in the outer peripheral direction by crimping and fixing described later. The electronic control unit housed inside the metal cover 12 is a power conversion circuit having a power supply circuit unit that generates a necessary power supply and a power switching element including a MOSFET or an IGBT that drives and controls the electric motor of the electric motor unit 8. It also consists of a control circuit unit that controls this power switching element, and the output terminal of the power switching element and the coil input terminal of the electric motor are electrically connected via a bus bar.

The connector terminal assembly 13 is exposed from a hole formed in the metal cover 12 on the end surface of the metal cover 12 on the opposite side of the motor housing 11. The metal cover 12 is formed so as to cover all of the electronic control units fixed to the end face side of the motor housing 11 and a part of the connector terminal assembly 13 for connecting the electronic control unit to an external device. Is designed to be mechanically and electrically protected.

The connector terminal assembly 13 is a resin connector made of synthetic resin, and the connector terminal assembly 13 and the metal cover 12 are liquidtightly engaged in the assembled state. For example, the two are pressure-welded and engaged via a seal ring made of silicon, whereby a liquid-tight structure can be ensured. Alternatively, liquid tightness can be ensured by forming a groove on the surface of the connector terminal assembly 13 for accommodating the end face of the metal cover, filling the groove with a liquid sealant, and accommodating the end face of the metal cover.

Further, the connector terminal assembly 13 is fixed to the fixing portion formed in the motor housing 11 by a fixing screw. The connector terminal assembly 13 includes a connector terminal forming unit 13A for power supply, a connector terminal forming unit 13B for a detection sensor, and a connector terminal forming unit 13C for transmitting a control state to an external device.

The electronically controlled assembly housed in the metal cover 12 is supplied with power from the power supply via the connector terminal forming portion 13A for power supply made of synthetic resin, and the detection sensors detect the operating state and the like. The signal is supplied via the connector terminal forming unit 13B for the detection sensor, and the control state signal of the current electric power steering device is transmitted via the connector terminal forming terminal 13C for transmitting the control state.

FIG. 3 shows an exploded perspective view of the electric power steering device 6. An annular iron side yoke (not shown) is fitted inside the motor housing 11, and an electric motor (not shown) is housed in the side yoke. The output unit 14 of the electric motor applies steering assist force to the rack via gears. Since the specific structure of the electric motor is well known, the description thereof is omitted here.

The motor housing 11 is made of an aluminum alloy, and functions as a heat sink member that releases heat generated by an electric motor and heat generated by a power supply circuit unit and a power conversion circuit unit, which will be described later, to the outside atmosphere. The electric motor unit 8 is composed of the electric motor and the motor housing 11.

An electronic control unit EC is attached to an end face portion 15 of the motor housing 11 on the opposite side of the output unit 14 of the electric motor unit 8. The electronic control unit EC includes a power conversion circuit unit 16, a power supply circuit unit 17, a control circuit unit 18, and a connector terminal assembly 13. The end face portion 15 of the motor housing 11 is integrally formed with the motor housing 11, but in addition to this, only the end face portion 15 may be formed separately and integrated with the motor housing 11 by screws or welding. Is.

Here, the power conversion circuit unit 16, the power conversion circuit unit 17, and the control circuit unit 18 form a redundant system, and form a dual system of a main electronic control unit and a sub electronic control unit. Normally, the electric motor is controlled and driven by the main electronic control unit, but when an abnormality or failure occurs in the main electronic control unit, the motor is switched to the sub-electronic control unit so that the electric motor is controlled and driven. It will be.

Therefore, as will be described later, normally, heat from the main electronic control unit is transferred to the motor housing 11, and when an abnormality or failure occurs in the main electronic control unit, the main electronic control unit stops and the sub-electronic control unit operates. The heat from the sub-electronic control unit is transferred to the motor housing 11.

However, although it is not adopted in this embodiment, the main electronic control unit and the sub electronic control unit are combined to function as a regular electronic control unit, and if an abnormality or failure occurs in one electronic control unit, the other electronic control unit is controlled. It is also possible to control and drive an electric motor with half the capacity of the unit. In this case, the capacity of the electric motor is halved, but the so-called "power steering function" is secured. Therefore, in the normal case, the heat of the main electronic control unit and the sub electronic control unit is transferred to the motor housing 11.

The electronic control unit EC is composed of a control circuit unit 18, a power supply circuit unit 17, a power conversion circuit unit 16, and a connector terminal assembly 13, and the power conversion circuit unit 16 and a power supply unit are directed away from the end face portion 15 side. The circuit unit 17, the control circuit unit 18, and the connector terminal assembly 13 are arranged in this order. The control circuit unit 18 generates a control signal for driving the switching element of the power conversion circuit unit 16, and is composed of a microcomputer, peripheral circuits, and the like. The power supply circuit unit 17 generates a power supply for driving the control circuit unit 18 and a power supply for the power conversion circuit unit 16, and is composed of a capacitor, a coil, a switching element, and the like. The power conversion circuit unit 16 adjusts the power flowing through the coil of the electric motor, and is composed of switching elements and the like that form the three-phase upper and lower arms.

The electric power conversion circuit unit 16 and the power supply circuit unit 17 mainly generate a large amount of heat in the electronic control unit EC, and the heat of the power conversion circuit unit 16 and the power supply circuit unit 17 is dissipated from the motor housing 11 made of an aluminum alloy. Is to be done. This detailed configuration will be described later with reference to FIGS. 4 to 9.

A connector terminal assembly 13 made of synthetic resin is provided between the control circuit unit 18 and the metal cover 12, and is connected to a vehicle battery (power supply) and an external other control device (not shown). Of course, it goes without saying that the connector terminal assembly 13 is connected to the power conversion circuit unit 16, the power supply circuit unit 17, and the control circuit unit 18.

The metal cover 12 has a function of accommodating the power conversion circuit unit 16, the power supply circuit unit 17, and the control circuit unit 18 and sealing them liquid-tightly. In the present embodiment, the metal cover 12 is crimped and fixed. It is fixed to the motor housing 11.

Next, the configuration and assembly method of each component will be described with reference to FIGS. 4 to 9. First, FIG. 4 shows the appearance of the motor housing 11, and FIG. 5 shows the axial cross section thereof.

In FIGS. 4 and 5, the motor housing 11 is formed in a cylindrical shape and closes the side peripheral surface portion 11A, the end surface portion 15 that closes one end of the side peripheral surface portion 11A, and the other end of the side peripheral surface portion 11A. It is composed of an end face portion 19. In the present embodiment, the motor housing 11 has a bottomed cylindrical shape, and the side peripheral surface portion 11A and the end surface portion 15 are integrally formed. Further, the end surface portion 19 has a function of a lid, and after the electric motor is housed in the side peripheral surface portion 11A, the other end of the side peripheral surface portion 11A is closed.

Further, an annular groove portion (hereinafter referred to as a motor housing side annular groove portion) 35 is provided on the entire peripheral surface of the end surface portion 15, and the opening of the metal cover 12 shown in FIG. 9 is provided in the motor housing side annular groove portion 35. The end (hereinafter referred to as an annular tip on the metal cover side) 37 is housed. The portion between the annular groove portion 35 on the motor housing side and the annular tip portion 37 on the metal cover side of the metal cover 12 is liquidtightly joined by a so-called liquid sealant.

As shown in FIG. 5, a stator 21 in which a coil 20 is wound around an iron core is fitted inside the side peripheral surface portion 11A of the motor housing 11, and a permanent magnet is embedded inside the stator 21. The rotor 22 is rotatably housed. A rotation shaft 23 is fixed to the rotor 22, one end of which is an output unit 14, and the other end of which is a rotation detection unit 24 for detecting the rotation phase and rotation speed of the rotation shaft 23. A permanent magnet is provided in the rotation detection unit 24, and penetrates through the through hole 25 provided in the end face portion 15 and protrudes to the outside. Then, the rotation phase and the rotation speed of the rotation shaft 23 are detected by a magnetic sensing portion composed of a GMR element or the like (not shown).

Returning to FIG. 4, the power conversion circuit section 16 (see FIG. 3) and the power dissipation section 17 (see FIG. 3) are on the surface of the end face portion 15 located on the opposite side of the rotating shaft 23 from the output section 14. 15A and 15B are formed. A substrate / connector fixing convex portion 26 is integrally planted at the four corners of the end face portion 15, and a screw hole 26S is formed inside.

The board / connector fixing convex portion 26 is provided for fixing the board of the control circuit unit 18 described later and the connector terminal assembly 13. Further, in the substrate / connector fixed convex portion 26 planted from the power conversion heat dissipation region 15A described later, a substrate receiving portion 27 having the same height in the axial direction as the power supply heat dissipation region 15B described later is formed on the substrate. A screw hole 27S is formed in the receiving portion 27. The substrate receiving portion 27 is for mounting and fixing the glass epoxy board 31 of the power supply circuit portion 17, which will be described later.

The radial plane region orthogonal to the rotation axis 23 forming the end face portion 15 is divided into two. One forms a power conversion heat dissipation region 15A to which a power conversion circuit unit 16 composed of a switching element such as a MOSFET is attached, and the other forms a power supply heat dissipation region 15B to which a power supply circuit unit 17 is attached. In the present embodiment, the power conversion heat dissipation area 15A has a larger area than the power supply heat dissipation area 15B. This is because the dual system is adopted as described above, so that the installation area of the power conversion circuit unit 16 is secured.

The power conversion heat dissipation region 15A and the power supply heat dissipation region 15B have steps having different heights in the axial direction (direction in which the rotating shaft 23 extends). That is, the power supply heat dissipation region 15B is formed with a step in the direction away from the power conversion heat dissipation region 15A when viewed in the direction of the rotating shaft 23 of the electric motor. This step is set to a length at which the power conversion circuit unit 16 and the power supply circuit unit 17 do not interfere with each other when the power supply circuit unit 17 is installed after the power conversion circuit unit 16 is installed.

In the power conversion heat dissipation region 15A, three elongated rectangular protruding heat radiation portions 28 are formed. The protruding heat radiating unit 28 is provided with a dual power conversion circuit unit 16 described later. Further, the protruding heat radiating portion 28 projects and extends in a direction away from the electric motor when viewed in the direction of the rotating shaft 23 of the electric motor.

Further, the power dissipation region 15B is flat, and a power supply circuit unit 17, which will be described later, is installed. Therefore, the protruding heat radiating unit 28 functions as a heat radiating unit that transfers the heat generated by the power conversion circuit unit 16 to the end face portion 15, and the heat radiating region 15B for power supply transfers the heat generated by the power supply circuit unit 17 to the end face portion 15. It functions as a heat radiating unit that transfers heat.

The protruding heat radiating unit 28 can be omitted. In this case, the power conversion heat radiating region 15A functions as a heat radiating unit that transfers the heat generated by the power conversion circuit unit 16 to the end face portion 15. However, in the present embodiment, the metal substrate of the power conversion circuit unit 16 is welded to the protruding heat radiating unit 28 by friction stir welding to ensure reliable fixing.

As described above, in the end face portion 15 of the motor housing 11 according to the present embodiment, the heat sink member can be omitted and the length in the axial direction can be shortened. Further, since the motor housing 11 has a sufficient heat capacity, the heat of the power supply circuit unit 17 and the power conversion circuit unit 16 can be efficiently dissipated to the outside.

Next, FIG. 6 shows a state in which the power conversion circuit unit 16 is installed in the ridge heat dissipation unit 28 (see FIG. 4). As shown in FIG. 6, a power conversion circuit unit 16 composed of a dual system is installed above the protruding heat radiating unit 28 (see FIG. 4) formed in the power conversion heat radiating region 15A. The switching element constituting the power conversion circuit unit 16 is mounted on a metal substrate (here, an aluminum-based metal is used), and is configured to easily dissipate heat. The metal substrate is welded to the protruding heat radiating portion 28 by friction stir welding.

Therefore, the metal substrate is firmly fixed to the protruding heat radiating section 28 (see FIG. 4), and the heat generated by the switching element can be efficiently transferred to the protruding heat radiating section 28 (see FIG. 4). The heat transferred to the protruding heat radiating portion 28 (see FIG. 4) is diffused to the power conversion radiating region 15A, further transferred to the side peripheral surface portion 11A of the motor housing 11, and radiated to the outside. Here, as described above, the height of the power conversion circuit unit 16 in the axial direction is lower than the height of the power supply heat dissipation region 15B, so that the power conversion circuit unit 16 does not interfere with the power supply circuit unit 17, which will be described later.

As described above, the power conversion circuit unit 16 is installed above the protruding heat radiating unit 28 formed in the power conversion heat radiating region 15A. Therefore, the heat generated by the switching element of the power conversion circuit unit 16 can be efficiently transferred to the protruding heat radiating unit 28. Further, the heat transferred to the protruding heat dissipation portion 28 is diffused to the power conversion heat dissipation region 15A, and is transferred to the side peripheral surface portion 11A of the motor housing 11 to be dissipated to the outside.

Next, FIG. 7 shows a state in which the power supply circuit unit 17 is installed from above the power conversion circuit unit 16. As shown in FIG. 7, a power supply circuit unit 17 is installed above the power dissipation region 15B. The capacitor 29, the coil 30, and the like constituting the power supply circuit unit 17 are mounted on the glass epoxy board 31. A dual system is also adopted for the power supply circuit unit 17, and as can be seen from the figure, a power supply circuit composed of a capacitor 29, a coil 30, and the like is formed symmetrically. An electric element such as a capacitor other than the switching element of the power conversion circuit 16 is mounted on the glass epoxy substrate 31.

The surface of the glass epoxy board 31 on the power supply heat dissipation region 15B (see FIG. 6) side is fixed to the end face portion 15 so as to be in contact with the power supply heat dissipation region 15B. As shown in FIG. 7, the fixing method is fixed by a fixing screw (not shown) in the screw hole 27S provided in the board receiving portion 27 of the board / connector fixing convex portion 26. Further, it is also fixed to a screw hole 27S provided in the power dissipation region 15B (see FIG. 6) by a fixing screw (not shown).

Since the power supply circuit portion 17 is formed of the glass epoxy substrate 31, double-sided mounting is possible. A rotation phase and rotation speed detection unit including a GMR element (not shown) and a detection circuit thereof are mounted on the surface of the glass epoxy substrate 31 on the power dissipation region 15B (see FIG. 6) side, and the rotation shaft 23 (see FIG. 6). In cooperation with the rotation detection unit 24 (see FIG. 5) provided in FIG. 5), the rotation phase and the rotation speed of rotation are detected.

In this way, since the glass epoxy board 31 is fixed so as to be in contact with the heat dissipation region 15B for power supply (see FIG. 6), the heat generated in the power supply circuit unit 17 is efficiently dissipated to the heat dissipation region 15B for power supply (FIG. 6). See) can be heat-transferred. The heat transferred to the heat dissipation region 15B for power supply (see FIG. 6) is diffused to the side peripheral surface portion 11A of the motor housing 11 and transferred to the outside to be dissipated to the outside. Here, by interposing any one of an adhesive having good heat transfer, a heat-dissipating grease, and a heat-dissipating sheet between the glass epoxy substrate 31 and the heat-dissipating region 15B for power supply (see FIG. 6), the heat transfer performance is further improved. Can be improved.

As described above, the power supply circuit unit 17 is installed above the power dissipation region 15B. The surface of the glass epoxy board 31 on which the circuit element of the power supply circuit portion 17 is placed on the power dissipation region 15B side is fixed to the end surface portion 15 so as to be in contact with the power supply heat dissipation region 15B. Therefore, the heat generated in the power supply circuit unit 17 can be efficiently transferred to the power dissipation region 15B. The heat transferred to the heat dissipation region 15B for power supply is diffused to the side peripheral surface portion 11A of the motor housing 11 and transferred to the outside so as to be dissipated to the outside.

Next, FIG. 8 shows a state in which the control circuit unit 18 is installed from above the power supply circuit unit 17. As shown in FIG. 8, a control circuit unit 18 is installed above the power supply circuit unit 17. The microcomputer 32 and the peripheral circuit 33 constituting the control circuit unit 18 are mounted on the glass epoxy board 34. A dual system is also adopted for the control circuit unit 18, and as can be seen from the figure, a control circuit composed of a microcomputer 32 and a peripheral circuit 33 is formed for each target. The microcomputer 32 and the peripheral circuit 33 may be provided on the surface of the glass epoxy board 34 on the power supply circuit 17 side.

As shown in FIG. 8, the glass epoxy board 34 is a fixing screw (not shown) sandwiched by a connector terminal assembly 13 in a screw hole 26S provided at the top of a board / connector fixing convex portion 26 (see FIG. 7). Between the glass epoxy board 31 of the power supply circuit unit 17 (see FIG. 7) and the glass epoxy board 34 of the control circuit unit 18, a capacitor 29, a coil 30 and the like of the power supply circuit unit 17 shown in FIG. It is a space to be placed.

Next, FIG. 9 shows a state in which the connector terminal assembly 13 is installed from above the control circuit unit 18. As shown in FIG. 9, a connector terminal assembly 13 is installed above the control source circuit unit 18. The connector terminal assembly 13 is fixed by the fixing screw 36 so as to sandwich the control circuit portion 18 in the screw hole provided at the top of the board / connector fixing convex portion 26. In this state, as shown in FIG. 3, the connector terminal assembly 13 is connected to the power conversion circuit unit 16, the power supply circuit unit 17, and the control circuit unit 18.

Further, after this, the metal cover side annular tip portion 37 of the metal cover 12 is housed in the motor housing side annular groove portion 35 of the motor housing 11 and is fixed by a crimping fixing portion provided along the outer peripheral direction of the metal cover 12. It is a thing. As shown in FIG. 10, the crimping fixing portions 38 are formed on the outer periphery of the metal cover 12 at intervals of approximately 120 ° about the axis of the rotating shaft 23.

Next, details of the joint portion between the crimping fixing portion 38 and the end face portion 15 of the metal cover 12 and the motor housing 11 will be described with reference to FIGS. 10 to 11. FIG. 10 shows the appearance of the electric power steering device 6 in a state where the motor housing 11 and the metal cover 12 are fixed by crimping and fixing, and FIG. 11 shows a cross section of a main part in the axial direction of FIG.

In FIG. 10, a plurality (three) crimping fixing portions 38 are formed on the outer peripheral surface of the metal cover 12. The crimping fixing portion 38 extends axially from the motor housing side annular groove portion 35 formed on the entire peripheral surface of the end surface portion 15 of the motor housing 11 toward the connector terminal assembly 13 side, and is a power conversion heat dissipation region 15A. The wall surface of the metal cover 12 is pushed by a pushing tool into a crimping groove (not shown) formed of a crimping groove or a crimping hole provided in a fixed wall 39 forming a heat dissipation region 15B for a power source, and is plastic. It is formed by being deformed and crimped. The axial positioning of the metal cover 12 is performed by using the connector assembly 13, and the wall surface of the metal cover 12 is pushed into the crimping recess by a pushing tool with the axial position of the metal cover 12 determined. It is designed to be crimped.

Further, as shown in FIG. 11, in the space formed by the annular groove portion 35 on the motor housing side in which the annular tip portion 37 on the metal cover side of the metal cover 12 is housed, the liquid sealant 40 for liquid sealing is placed. It is filled without gaps. Therefore, since a liquid-tight seal region is formed between the crimping fixing portion 38 and the metal cover-side annular tip portion 37 of the metal cover 12, salt water or the like is prevented from entering in the seal region. Therefore, since salt water or the like does not infiltrate into the crimping and fixing portion 38, corrosion of the crimping and fixing portion 38 is suppressed, and mechanical reliability can be improved. Further, since the infiltration of salt water or the like into the electronic control unit 9 is suppressed, it is possible to improve the electrical reliability at the same time.

On the other hand, on the surface of the connector assembly 13 facing the metal cover 12, a connector-side storage groove 42 for accommodating the upper surface-side annular tip portion 41 of the metal cover 12 is formed, and the liquid sealing material 40 is filled. The liquid-tight structure is secured in a state where the annular tip portion 41 on the upper surface side of the metal cover 12 is housed in the storage groove 42 on the connector side. Alternatively, a liquidtight structure can be secured by interposing a seal ring between the connector-side storage groove 42 and the upper surface-side annular tip portion 41.

Further, the connector assembly 13 is formed with a connection hole 43 for connecting the inside of the metal cover 12 and the external environment area outside the metal cover 12. The connection hole 43 is formed not as a minute gap between the metal connector terminal and the synthetic resin, but as a hole having a sufficient air flow area.

Further, the formation position of the connection hole 43 is a position where the mating side connector terminal connected to the connector assembly 13 is fitted, whereby the connection hole 43 is surrounded by the mating side connector terminal and sealed (in a completely sealed state). Therefore, it is possible to reduce the influence of flying stones and water damage caused by the running of the automobile.

Further, the connection hole 43 can be sealed with a liquid sealant after the metal cover 12 is fixed to the motor housing 11. As a result, it is possible to prevent water or the like from entering the metal cover 12. The connection hole 43 is formed of a connection hole portion 43L having a large distribution area and a connection hole portion 43S having a small distribution area connected to the connection hole portion 43L.

The connection hole portion 43L having a large distribution area is connected to the external environment area, and the connection hole portion 43S having a small distribution area is connected to the inside of the metal cover. Therefore, when the connection hole portion 43L having a large distribution area is sealed with the liquid sealant after the metal cover 12 is fixed to the motor housing 11, the liquid sealant is contained in the metal case 12 by the connection hole portion 43S having a small distribution area. It is possible to suppress the inflow to.

In the above configuration, the liquid seal member 40 is provided with a required viscosity so that it can flow. First, the liquid sealant 40 is poured into the annular groove portion 35 on the motor housing side, and the liquid seal member 40 is poured into the annular groove portion 35 on the motor housing side. In this state, the metal cover-side annular tip portion 37 of the metal cover 12 enters and is stored in the motor housing-side annular groove portion 35. Then, as the metal cover side annular tip 37 enters, the liquid sealant 40 flows so as to fill the gap between the metal cover side annular tip 37 and the side wall of the motor housing side annular groove 35. be.

At this time, since the air in the metal cover 12 passes through the connection hole 43 formed in the connector assembly 13 and is released to the external environment area, the pressure of the air in the metal cover 12 does not increase, and the liquid sealant 40 Will be suppressed from pushing out. By forming the connection hole 43 connecting the inside of the metal cover 12 and the external environment area in the connector assembly 13 in this way, the compressed pressure of the air in the metal cover 12 generated when the metal cover 12 is attached is externally controlled. It can be released to the environmental area, thereby suppressing the liquid sealant 40 from being pushed out. Therefore, since a sufficient sealing function can be obtained, it is possible to improve the electrical reliability.

In the above-described embodiment, the motor housing side annular groove portion 35 is formed so as to project toward the outer peripheral side of the end face portion 15 of the motor housing 11, but the motor housing side annular groove portion 35 is used as shown in FIG. Is also possible.

In FIG. 12, the motor housing side annular groove portion 35A formed on the outer peripheral surface of the end surface portion 15 of the motor housing 11 is in the radial direction orthogonal to the axis of the motor housing 11 which is the same as the axis of the rotating shaft 23 (see FIG. 11). It is formed inwardly in a shape that is recessed (recessed inward) by a predetermined distance from the fixed wall 39. The metal cover-side annular tip portion 37 of the metal cover 12 is arranged so as to face the motor housing-side annular groove portion 35A. Further, a liquid sealing material 40 is filled between the annular tip portion 37 on the metal cover side and the annular groove portion 35A on the motor housing side. Even in such a configuration, the configuration of the present embodiment can be applied.

The liquid sealant 40 for liquid tightness uses a synthetic resin having adhesiveness, and in this embodiment, a silicone rubber-based elastic adhesive is used. Silicone rubber-based elastic adhesives have the property of absorbing stress such as external vibration and impact, and making it difficult for stress to concentrate on the bonding interface. For this reason, in the case of an electric power steering device that is subject to vibration, impact, etc., the adhesive interface may peel off and the liquidtight function may be lost. The risk of loss of dense function can be reduced. Further, in the present embodiment, since the sealing is performed with the liquid sealing agent 40 having adhesiveness, the liquid-tightening O-ring that has been conventionally used can be omitted. Therefore, it is not necessary to form a storage groove for accommodating the O-ring in the fixed wall 39, and it is possible to suppress an increase in manufacturing cost.

The silicone-based elastic adhesive (liquid sealant) 40 may be a liquid gasket (FIPG: FORMED IN PLACE GASKET) having an adhesive function, and is made of a material that can be cured at room temperature or by heating. You can use things.

According to the present embodiment, since the metal cover 12 and the motor housing 11 are fixed by crimping and fixing without using fixing screws, the appearance shape can be made small and the weight can be reduced. Further, when an O-ring is used, it is necessary to form a storage groove for accommodating the O-ring, but in the case of this embodiment, since the O-ring is not used, processing of the storage groove or the like is not required, and the manufacturing cost rises. It can be suppressed.

By using the liquid sealant 40 as a highly heat-dissipating liquid sealant 40 kneaded with a material having good heat transfer properties such as alumina, the adhesive area is large, and the heat dissipation region 15A for power conversion and heat dissipation for power supply are generated. The heat of the region 15B can be efficiently dissipated to the metal cover 12. As a result, heat from the electric components constituting the power supply circuit unit 17 and the power conversion circuit unit 16 can be efficiently dissipated to the outside, and miniaturization becomes possible.

In the above-described embodiment, the crimping fixing portions 38 are formed at three places as the fixing means for fixing the metal cover 11 and the motor housing 11 without using the fixing screws, but the crimping fixing portions are formed over the entire circumference. It is also possible to do.

As described above, according to the present invention, an electronic control unit that controls the electric motor, an electronic control unit, and an external device are located on the end face portion of the metal motor housing on the side opposite to the output unit of the rotary shaft of the electric motor. A resin connector for connecting the motor housing is provided, and a motor housing side annular groove portion composed of an annular groove is formed on the outer peripheral surface of the end face portion of the motor housing, and the electronic control unit is liquidally engaged with the outer periphery of the resin connector. A state in which a metal cover-side annular tip facing the annular groove of the motor housing-side annular groove is formed at the open end of the metal cover covering the motor housing, and the metal cover-side annular tip is arranged facing the motor housing-side annular groove. A liquid sealant is filled between the annular groove on the motor housing side and the annular tip on the metal cover side, and a connection hole is formed in the resin connector to connect the inside of the metal cover and the external environment area. did.

According to this, by forming a connection hole connecting the inside of the metal cover and the external environment area in the resin connector, the compressed pressure of the air inside the metal cover generated when the metal cover is attached is released to the external environment area. This makes it possible to prevent the liquid sealant from being pushed out. Therefore, since this sealing function can be sufficiently obtained, it is possible to improve the electrical reliability.

The present invention is not limited to the above-described embodiment, and includes various modifications. For example, the above-described embodiment has been described in detail in order to explain the present invention in an easy-to-understand manner, and is not necessarily limited to the one including all the described configurations. Further, it is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. Further, it is possible to add / delete / replace a part of the configuration of each embodiment with another configuration.

6 ... Electric power steering device, 8 ... Electric motor unit, 9 ... Electronic control unit, 11 ... Motor housing, 12 ... Metal cover, 13 ... Connector terminal assembly, 14 ... Output unit, 15 ... End face part, 15A ... Power conversion Heat dissipation area for 15B ... Heat dissipation area for power supply, 16 ... Power conversion circuit section, 17 ... Power supply circuit section, 18 ... Control circuit section, 19 ... End face section, 20 ... Coil, 21 ... Stator, 22 ... Rotor, 23 ... Rotation Shaft, 24 ... Rotation detection part, 25 ... Through hole, 26 ... Board / connector fixed convex part, 27 ... Board receiving part, 28 ... Projective heat dissipation part, 29 ... Condenser, 30 ... Coil, 31 ... Glass epoxy board, 32 ... Mike computer, 33 ... Peripheral circuit, 34 ... Glass epoxy substrate, 35 ... Motor housing side annular groove, 36 ... Fixing screw, 37 ... Metal cover side annular tip, 38 ... Cramping fixing, 39 ... Fixed wall, 40 … Liquid sealant, 41… top surface side annular tip, 42… connector side storage groove, 43… connection hole.

Claims (10)

To drive the motor housing in which the electric motor for driving the mechanical control element is housed, and the electric motor arranged on the end face portion of the motor housing on the side opposite to the output portion of the rotation shaft of the electric motor. An electric drive device including an electronic control unit, a connector for connecting the electronic control unit to an external device, and a cover for covering the electronic control unit.
The motor housing includes a motor housing side annular groove portion formed of an annular groove formed on an outer peripheral surface of the end surface portion of the motor housing.
The cover is formed at the open end of the cover and includes a cover-side annular tip portion of the motor housing-side annular groove portion facing the annular groove.
A liquid sealant is filled between the motor housing side annular groove portion and the cover side annular tip portion in a state where the cover side annular tip portion is arranged to face the motor housing side annular groove portion.
The connector is formed with a connection hole connecting the inside of the cover and the external environment area, and with the cover fixed to the motor housing, at least the external environment area side of the connection hole is sealed with a liquid sealant. Have been
An electric drive device characterized by that. In the electric drive device according to claim 1,
The connection hole formed in the connector is a position where a mating connector terminal connected to the connector is fitted, and the connection hole is surrounded by the mating connector terminal. Drive device. In the electric drive device according to claim 1,
The connection hole is formed of a connection hole portion having a large distribution area and a connection hole portion having a small distribution area connected to the connection hole portion, and the connection hole portion having a large distribution area is connected to the external environment area and is connected to the distribution. An electric drive device characterized in that a connection hole portion having a small area is connected to the inside of the cover. In the electric drive device according to claim 3,
The electric drive device is characterized in that the connection hole portion having a large distribution area is sealed with a liquid sealant while the cover is fixed to the motor housing. The electric drive device according to any one of claims 1 to 4.
The cover is made of metal, and a plurality of crimping fixing portions are formed on the outer peripheral surface of the cover.
The crimping fixing portion is an electric drive device characterized in that the crimping fixing portion is formed by pushing the wall surface of the cover into a crimping recess provided in the end face portion of the motor housing and plastically deforming the cover. An electric motor that applies steering assist force to the steering shaft based on the output from the torque sensor that detects the rotation direction and rotation torque of the steering shaft, the motor housing in which the electric motor is housed, and the rotation of the electric motor. An electronic control unit for driving the electric motor arranged on the end face side of the motor housing on the side opposite to the output unit of the shaft, a connector for connecting the electronic control unit and an external device, and the electronic control. It is an electric power steering device equipped with a cover that covers the part .
The motor housing includes a motor housing side annular groove portion formed of an annular groove formed on an outer peripheral surface of the end surface portion of the motor housing.
The cover is formed at the open end of the cover and includes a cover-side annular tip portion of the motor housing-side annular groove portion facing the annular groove.
A liquid sealant is filled between the motor housing side annular groove portion and the cover side annular tip portion in a state where the cover side annular tip portion is arranged to face the motor housing side annular groove portion.
The connector is formed with a connection hole connecting the inside of the cover and the external environment area, and with the cover fixed to the motor housing, at least the external environment area side of the connection hole is sealed with a liquid sealant. Have been
An electric power steering device characterized by this. In the electric power steering device according to claim 6,
The connection hole formed in the connector is a position where a mating connector terminal connected to the connector is fitted, and the connection hole is surrounded by the mating connector terminal. Power steering device. In the electric power steering device according to claim 6,
The connection hole is formed of a connection hole portion having a large distribution area and a connection hole portion having a small distribution area connected to the connection hole portion, and the connection hole portion having a large distribution area is connected to the external environment area and is connected to the distribution. An electric power steering device characterized in that a connection hole having a small area is connected to the inside of the cover. In the electric power steering apparatus according to claim 8,
An electric power steering device characterized in that the connection hole portion having a large distribution area is sealed with a liquid sealant while the cover is fixed to the motor housing. The electric power steering apparatus according to any one of claims 6 to 9.
The cover is made of metal, and a plurality of crimping fixing portions are formed on the outer peripheral surface of the cover.
The crimping fixing portion is an electric power steering device characterized in that the crimping fixing portion is formed by pushing the wall surface of the cover into a crimping recess provided in the end face portion of the motor housing and plastically deforming the cover.

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